Chemical reactor with high speed rotary mixing, for catalytic thermal conversion of organic materials into diesel and other liquid fuels, and applications thereof

ABSTRACT

Chemical reactor with high speed rotary mixing, system thereof, and method thereof, for catalytic thermal conversion of organic (hydrocarbon-containing) materials (coal, plastics, rubber, plant matter, wood shavings, biomass, organic wastes) into diesel and other liquid fuels (automobile or/and jet engine fuels). Relevant to non-conventional commercial scale production of liquid fuels, and to commercial scale processing and disposing of organic waste materials. Chemical reactor includes: integrated combination of a reactor stationary assembly (RSA), having only stationary components remaining stationary during chemical reactor operation, and a reactor rotary mixing assembly (RRMA), having only rotatable components rotating during chemical reactor operation. May include anti-abrasion shield for shielding inner surface of reactor central housing from abrasion during chemical reactor operation. Rotor may include a reinforcement disc. Rotor blades or/and reinforcement disc may include rotor-based performance and process control structural features (openings, or/and protrusions, or/and depressions), for additionally controlling performance of the rotor.

RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.16/996,628, filed Aug. 18, 2020, which claims the benefit of priorityunder 35 USC 119(e) of U.S. Provisional Patent Application No.62/994,099, filed Mar. 24, 2020, the contents of which are incorporatedherein by reference in their entirety.

FIELD OF THE INVENTION

The present invention, in some embodiments thereof, relates to chemicalreactors that include high speed rotary mixing therein, and applicationsthereof, for catalytic thermal conversion of organic (i.e.,hydrocarbon-containing) materials into diesel and other liquid fuels,and more particularly, but not exclusively, to a chemical reactor withhigh speed rotary mixing, a system thereof, and a method thereof, forcatalytic thermal conversion of organic materials (e.g., coal, plastics,rubber, plant matter, wood shavings, biomass, organic wastes, amongvarious other possible organic materials) into diesel and other liquidfuels (e.g., automobile or/and jet engine fuels). Some embodiments ofthe present invention are particularly relevant to fields of technologythat involve non-conventional commercial scale production of liquid fuelproducts, and that involve environmentally acceptable commercial scaleprocessing and disposing of organic waste materials.

BACKGROUND OF THE INVENTION

Catalytic thermal conversion (i.e., catalytically expedited thermalprocesses of cracking, degradation, decomposition, depolymerization) ofheavy to light organic (i.e., hydrocarbon-containing) materials is awell established and widely used technique for producing a wide varietyof numerous chemical products. Such technique, particularly performed atthermal conversion temperatures ordinarily no higher than about 400° C.inside the chemical reactor (i.e., inside a chemical reaction chamberthereof, wherein take place the various chemical reactions), forproducing diesel and other liquid fuels, is also known as the KDV(Katalytische Drucklose Verolung) Technique, and as the NTK (NiederTemperatur Konvertierung) Technique. In such techniques, the necessarythermal conversion temperatures inside the chemical reactor (chemicalreaction chamber) are achieved by using designated heating equipment(heaters located outside of the chemical reactor) that externally heatthe chemical reactor (chemical reaction chamber) and its contents.

Performance of such techniques by including and exploiting high speedrotary mixing of reactor contents inside the chemical reactor, forgenerating and providing the necessary thermal conversion temperaturesinside the chemical reactor, was initially developed and taught about byKoch (for example, as disclosed in U.S. Pat. No. 7,473,348, and in U.S.Pat. Appl. Pub. Nos. 2007/0131585 A1, 2008/0116116 A1, and 2011/0297582A1). Such newer techniques involve designing, constructing, andoperating the chemical reactor with high speed rotary mixing equipment,particularly, pumps, rotor shafts, and rotors (impellers) having blades(vanes).

Although such newer catalytic thermal conversion techniques have the twoimportant advantages of generating heat energy and mechanical mixinginside the chemical reactor (chemical reaction chamber), they also haveseveral significant disadvantages and limitations which have yet to befully, or at least effectively, overcome. Main, but, not the only,disadvantages and limitations are based on low energy efficiency (due tohigh energy consumption) of the overall process encompassing initialinput conversion of the organic materials and output production ofdiesel and other liquid fuels, and on low durability (short lifeexpectancy of the overall process due to extensive physical and chemical‘wear and tear’) of the high speed rotary mixing equipment. At leastthese two main disadvantages and limitations preclude economicallyfeasible commercial (industrial) scale operation of even the newercatalytic thermal conversion techniques.

Several ‘substantial’ attempts have been made in order to address andovercome such main disadvantages and limitations, for example, asdisclosed in UK Patent No. GB 2473500 B, and in PCT Pat. Appl. Int'l.Pub. Nos.: WO 2014/087238, WO 2018/138194 A1, and WO 2018/228619 A1(U.S. Pat. Appl. Pub. No. US 2020/0095505 A1).

Despite such attempts, and in view of at least the above stated maindisadvantages and limitations, there is an on-going need for developingand implementing new and improved chemical reactors that include highspeed rotary mixing therein, systems thereof, and methods thereof, forcatalytic thermal conversion of organic materials into diesel and otherliquid fuels, which are applicable to economically feasible commercial(industrial) scale operation. Such need is particularly relevant tofields of technology that involve non-conventional commercial scaleproduction of liquid fuel products, and that involve environmentallyacceptable commercial scale processing and disposing of organic wastematerials.

SUMMARY OF THE INVENTION

The present invention, in some embodiments thereof, relates to achemical reactor with high speed rotary mixing, a system thereof, and amethod thereof, for catalytic thermal conversion of organic (i.e.,hydrocarbon-containing) materials (e.g., coal, plastics, rubber, plantmatter, wood shavings, biomass, organic wastes, among various otherpossible organic materials) into diesel and other liquid fuels (e.g.,automobile or/and jet engine fuels). Some embodiments of the presentinvention are particularly relevant to fields of technology that involvenon-conventional commercial scale production of liquid fuel products,and that involve environmentally acceptable commercial scale processingand disposing of organic waste materials.

According to an aspect of some embodiments of the present invention,there is provided a chemical reactor with high speed rotary mixing, forcatalytic thermal conversion of organic materials into diesel and otherliquid fuels, the chemical reactor comprising:

a reactor stationary assembly (RSA), configured with only stationarycomponents that remain stationary during operation of the chemicalreactor, and comprising: a reactor central housing, configured as atubular member longitudinally extending proximally and distally, havingproximal and distal open ends; proximal and distal reactor input/outputmanifolds, each of the manifolds is configured with a longitudinallydirected rotor shaft passageway, and has a respective distal or proximalside that covers, and is sealed to, the reactor central housing proximalor distal open end, and each of the manifolds is housed in a respectiveproximal or distal manifold housing having proximal and distal sides andconfigured with a longitudinally directed rotor shaft passageway; theproximal and distal manifold housings, with the respective proximal anddistal manifolds housed therein, are oppositely located and parallel toeach other with the reactor central housing longitudinally extendingtherebetween; proximal and distal dynamic seal housings, each of thedynamic seal housings is configured with a longitudinally directed rotorshaft passageway, and has a respective distal or proximal side that issealed to the proximal or distal side of the proximal or distal manifoldhousing, respectively, the proximal and distal dynamic seal housings arelocated opposite and parallel to each other relative to the reactorcentral housing; and proximal and distal lubricated cartridge sealhousings, each of the cartridge seal housings is configured with alongitudinally directed rotor shaft passageway, and has a respectivedistal or proximal side that is sealed to the proximal or distal side ofthe proximal or distal dynamic seal housing, respectively, the proximaland distal cartridge seal housings are located opposite and parallel toeach other relative to the reactor central housing; and

a reactor rotary mixing assembly (RRMA), configured with only rotatablecomponents that rotate during operation of the chemical reactor, andcomprising: a rotor, housed inside of the reactor central housing, andconfigured with a rotor tubular portion longitudinally extendingproximally and distally with proximal and distal open ends, the rotorincludes a plurality of equally sized radially curved rotor blades, thatextend radially from, and longitudinally along, the outercircumferential periphery of the rotor tubular portion; proximal anddistal rotatable dynamic seals, each of the dynamic seals is configuredwith a longitudinally directed rotor shaft passageway, and is housedinside of the proximal or distal dynamic seal housing, respectively;proximal and distal rotatable lubricated cartridge seals, each of thecartridge seals is configured with a longitudinally directed rotor shaftpassageway, and is housed inside of the proximal or distal lubricatedcartridge seal housing, respectively; and a rotatable rotor shaft,longitudinally supported via the proximal and distal lubricatedcartridge seal housings, and longitudinally passing through the reactorcentral housing proximal and distal open ends, and through the rotorshaft passageways of the proximal and distal reactor input/outputmanifolds and the housings thereof, of the proximal and distal dynamicseals and the housings thereof, of the proximal and distal lubricatedcartridge seals and the housings thereof, and through the rotor proximaland distal open ends, the rotor shaft is fixedly connected to the rotortubular portion so as to facilitate controllable rotation of the rotorduring operation of the chemical reactor.

According to an aspect of some embodiments of the present invention,there is provided a reactor rotary mixing assembly, for use in achemical reactor with high speed rotary mixing, for catalytic thermalconversion of organic materials into diesel and other liquid fuels, thereactor rotary mixing assembly comprising: a rotor, configured with atubular portion longitudinally extending proximally and distally withproximal and distal open ends, the rotor includes a plurality of equallysized radially curved rotor blades, that extend radially from, andlongitudinally along, the outer circumferential periphery of the rotortubular portion; proximal and distal rotatable dynamic seals, configuredwith respective longitudinally directed rotor shaft passageways, andlocated opposite and parallel to each other with the rotor tubularmember longitudinally positioned therebetween; proximal and distalrotatable lubricated cartridge seals, configured with respectivelongitudinally directed rotor shaft passageways, and located oppositeand parallel to each other with the proximal and distal dynamic sealslongitudinally positioned therebetween; and a rotatable rotor shaft,longitudinally passing through the rotor proximal and distal circularopen ends, and through the rotor shaft passageways of the proximal anddistal dynamic seals, and of the proximal and distal lubricatedcartridge seals, the rotor shaft is fixedly connected to the rotortubular portion so as to facilitate controllable rotation of the rotorduring operation of the chemical reactor.

According to some embodiments of the invention, the reactor stationaryassembly additionally includes an anti-abrasion shield that shields thetubular inner surface of the reactor central housing from abrasionduring operation of the chemical reactor, the abrasion shield isconfigured as a tubular member longitudinally extending proximally anddistally inside of the reactor central housing, having a proximalcircular open end covered by, and sealed to, the distal circular side ofthe proximal reactor input/output manifold, and having a distal circularopen end covered by, and sealed to, the proximal circular side of thedistal reactor input/output manifold.

According to some embodiments of the invention, at least one of therotor blades is configured with at least one rotor-based performance andprocess control structural feature selected from the group consistingof: openings, protrusions, and depressions, whereby the rotor-basedperformance and process control structural features facilitatecontrolling performance of the rotor, so as to provide an additionallayer or level of control of chemical reaction related physicochemicalprocesses of mass and heat transfer, mixing and degradation, andcatalytic chemical conversion, taking place inside of the reactorcentral housing during operation of the chemical reactor.

According to some embodiments of the invention, the openings are in aform of holes or slits passing entirely through the radially curvedthickness of the at least one of the rotor blades.

According to some embodiments of the invention, the protrusions are in aform of teeth or spikes, or mounds protruding or projecting out from theradially curved thickness of the at least one of the rotor blades.According to some embodiments of the invention, the protrusions areconfigured only on the leading or front convex side of the at least oneof the rotor blades, and face toward, and in, the direction of rotationof the rotor.

According to some embodiments of the invention, the depressions are in aform of inverse mounds protruding or projecting partly into, notentirely through, the radially curved thickness of the at least one ofthe rotor blades. According to some embodiments of the invention, thedepressions are configured only in the leading or front convex sides ofthe rotor blades, and face toward, and in, the direction of rotation ofthe rotor.

According to some embodiments of the invention, the rotor includes arotor central reinforcement disc, having proximal and distal circularfaces, and a central opening concentric with the circumferentialperiphery of the rotor tubular portion, thereby facilitatinglongitudinal passage therethrough of the rotor shaft, the rotor centralreinforcement disc transversely bisects the longitudinal lengths of therotor blades, and the outer circumferential periphery of the rotorcentral reinforcement disc is transverse to, and coincides with, theradial outer ends of the rotor blades.

According to some embodiments of the invention, the rotor centralreinforcement disc is configured with at least one rotor-basedperformance and process control structural feature selected from thegroup consisting of: openings, protrusions, and depressions, whereby therotor-based performance and process control structural featuresfacilitate controlling performance of the rotor, so as to provideadditional control of chemical reaction related physicochemicalprocesses of mass and heat transfer, mixing and degradation, andcatalytic chemical conversion, taking place inside of the reactorcentral housing during operation of the chemical reactor.

According to some embodiments of the invention, in the rotor centralreinforcement disc, the openings are in a form of holes or slits passingentirely through the thickness of the rotor central reinforcement disc.

According to some embodiments of the invention, in the rotor centralreinforcement disc, the protrusions are in a form of teeth or spikes, ormounds protruding or projecting out from the thickness of the rotorcentral reinforcement disc. According to some embodiments of theinvention, in the rotor central reinforcement disc, the protrusions areconfigured in the rotor central reinforcement disc proximal circularside or/and in the distal circular side.

According to some embodiments of the invention, in the rotor centralreinforcement disc, the depressions are in a form of inverse moundsprotruding or projecting partly into, not entirely through, thethickness of the rotor central reinforcement disc. According to someembodiments of the invention, in the rotor central reinforcement disc,the depressions are configured in the rotor central reinforcement discproximal circular side or/and in the distal circular side.

According to some embodiments of the invention, the rotor shaft isoperably connectable to a rotor shaft drive unit that drives and rotatesthe rotor shaft.

According to some embodiments of the invention, the chemical reactor isadditionally operably connectable to a catalytic thermal conversionsystem.

According to an aspect of some embodiments of the present invention,there is provided a system for catalytically thermally convertingorganic materials into diesel and other liquid fuels, the systemcomprising: a chemical reactor that includes a reactor stationaryassembly (RSA), configured with only stationary components that remainstationary during operation of the chemical reactor, and a reactorrotary mixing assembly (RRMA), configured with only rotatable componentsthat rotate during operation of the chemical reactor; a rotor shaftdrive unit configured for driving and rotating the reactor rotary mixingassembly (RRMA) relative to the reactor stationary assembly (RSA); andcatalytic conversion system process units, operatively connected to thechemical reactor. In exemplary embodiments, the catalytic thermalconversion system additionally includes a process control anddata-information processing unit, operatively connected to, and,configured for controlling operation of and processing data-informationassociated with, the other units (and components therein) of thecatalytic thermal conversion system, namely, the chemical reactor, therotor shaft drive unit, and the catalytic thermal conversion systemprocess units.

According to an aspect of some embodiments of the present invention,there is provided a method for catalytically thermally convertingorganic materials into diesel and other liquid fuels, the methodcomprising: providing a chemical reactor that includes a reactorstationary assembly (RSA), configured with only stationary componentsthat remain stationary during operation of the chemical reactor, and areactor rotary mixing assembly (RRMA), configured with only rotatablecomponents that rotate during operation of the chemical reactor;operatively connecting the reactor rotary mixing assembly (RRMA) to arotor shaft drive unit, so as to drive and rotate the reactor rotarymixing assembly (RRMA) relative to the reactor stationary assembly(RSA); operatively connecting the chemical reactor to catalyticconversion system process units; and operating the chemical reactor andthe catalytic conversion system process units, so as to thermallyconvert organic materials into diesel and other liquid fuels. Inexemplary embodiments, the method further includes controlling operationof and processing data-information associated with, the chemicalreactor, the rotor shaft drive unit, and the catalytic thermalconversion system process units.

All technical or/and scientific words, terms, or/and phrases, usedherein have the same or similar meaning as commonly understood by one ofordinary skill in the art to which the invention pertains, unlessotherwise specifically defined or stated herein. Exemplary embodimentsof apparatuses (devices, systems, components thereof), equipment,materials, and methods (steps, procedures), illustratively describedherein are exemplary and illustrative only and are not intended to benecessarily limiting. Although apparatuses, equipment, materials, andmethods, equivalent or similar to those described herein can be used inpracticing or/and testing embodiments of the invention, exemplaryapparatuses, equipment, materials, and methods, are illustrativelydescribed below. In case of conflict, the patent specification,including definitions, will control.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Some embodiments of the present invention are herein described, by wayof example only, with reference to the accompanying drawings. Withspecific reference now to the drawings in detail, it is stressed thatthe particulars shown are by way of example and for purposes ofillustrative description of some embodiments of the present invention.In this regard, the description taken together with the accompanyingdrawings make apparent to those skilled in the art how some embodimentsof the present invention may be practiced.

In the drawings:

FIGS. 1, and 2A-2B, are schematic partly cut-away side, and perspective,views, respectively, of the chemical reactor with high speed rotarymixing, for catalytic conversion of organic materials into diesel andother liquid fuels, in accordance with some embodiments of theinvention;

FIG. 3 is a schematic exploded perspective views of the chemicalreactor, and of both the reactor stationary assembly (RSA) and thereactor rotary mixing assembly (RRMA), and components thereof, alongwith highlighting those components which form and define the chemicalreaction chamber, in accordance with some embodiments of the invention;

FIGS. 4 and 5 are schematic exploded perspective views and of thereactor stationary assembly (RSA), and of the reactor rotary mixingassembly (RRMA), respectively, and components thereof, of the chemicalreactor, in accordance with some embodiments of the invention;

FIGS. 6, 7, and 8 are schematic side, perspective, and distal frontcut-away, views, respectively, of the chemical reactor, highlightinglatitudinal or radial (transverse) offset of indicated chemical reactorcomponents, in accordance with some embodiments of the invention;

FIGS. 9A and 9B are schematic perspective and side views, respectively,of the reactor central housing (part of the reactor stationary assembly(RSA)), in accordance with some embodiments of the invention;

FIGS. 10A and 10B are schematic proximal front and distal front views,respectively, of the distal reactor input/output manifold (part of thereactor stationary assembly (RSA)), in accordance with some embodimentsof the invention;

FIGS. 11A and 11B are schematic proximal front and distal front views,respectively, of the distal manifold housing (part of the reactorstationary assembly (RSA)), in accordance with some embodiments of theinvention;

FIGS. 12A and 12B are schematic proximal front and distal front views,respectively, of the proximal reactor input/output manifold (part of thereactor stationary assembly (RSA)), in accordance with some embodimentsof the invention;

FIGS. 13A and 13B are schematic proximal front and distal front views,respectively, of the proximal manifold housing (part of the reactorstationary assembly (RSA)), in accordance with some embodiments of theinvention;

FIGS. 14A and 14B are schematic perspective and side views,respectively, of the distal dynamic seal housing (part of the reactorstationary assembly (RSA)), in accordance with some embodiments of theinvention;

FIG. 14C is a schematic of the proximal front view of the proximaldynamic seal housing, and also of the distal front view of the distaldynamic seal housing, in accordance with some embodiments of theinvention;

FIG. 14D is a schematic of the distal front view of the proximal dynamicseal housing, and also of the proximal front view of the distal dynamicseal housing, in accordance with some embodiments of the invention;

FIGS. 15A and 15B are schematic perspective and side views,respectively, of the distal lubricated cartridge seal housing (part ofthe reactor stationary assembly (RSA)), in accordance with someembodiments of the invention;

FIG. 15C is a schematic of the proximal front view of the proximallubricated cartridge seal housing, and also of the distal front view ofthe distal lubricated cartridge seal housing, in accordance with someembodiments of the invention;

FIG. 15D is a schematic of the distal front view of the proximallubricated cartridge seal housing, and also of the proximal front viewof the distal lubricated cartridge seal housing, in accordance with someembodiments of the invention;

FIGS. 16A, 16B, and 16C are schematic tilted front, side, andperspective views, respectively, of the anti-abrasion shield (part ofthe reactor stationary assembly (RSA)), in accordance with someembodiments of the invention;

FIGS. 17A and 17B are schematic perspective and side views,respectively, of the rotor 140 (part of the reactor rotary mixingassembly (RRMA)), in accordance with some embodiments of the invention;

FIGS. 18A and 18B are schematic perspective and side views,respectively, of the rotor 140 (part of the reactor rotary mixingassembly (RRMA)), with a rotor central reinforcement disc, in accordancewith some embodiments of the invention;

FIGS. 19A and 19B are schematic perspective and side views,respectively, of the distal rotatable dynamic seal (part of the reactorstationary assembly (RRMA)), in accordance with some embodiments of theinvention;

FIG. 19C is a schematic of the proximal front view of the proximalrotatable dynamic seal, and also of the distal front view of the distalrotatable dynamic seal, in accordance with some embodiments of theinvention;

FIG. 19D is a schematic of the distal front view of the proximalrotatable dynamic seal, and also of the proximal front view of thedistal rotatable dynamic seal, in accordance with some embodiments ofthe invention;

FIGS. 20A and 20B are schematic perspective and side views,respectively, of the distal rotatable lubricated cartridge seal (part ofthe reactor rotary mixing assembly (RRMA)), in accordance with someembodiments of the invention;

FIGS. 21A and 21B are schematic perspective and top views, respectively,of the rotatable rotor shaft (part of the reactor rotary mixing assembly(RRMA)), in accordance with some embodiments of the invention;

FIGS. 22A and 22B are schematic perspective and side views,respectively, of the distal rotatable cartridge bearing (part of thereactor rotary mixing assembly (RRMA)), in accordance with someembodiments of the invention;

FIG. 23 is a schematic perspective view of a distal rotatable paired setof a locknut and a locknut washer (part of the reactor rotary mixingassembly (RRMA)), in accordance with some embodiments of the invention;

FIGS. 24A and 24B are schematic perspective views of the rotor 140, withrotor-based performance and process control structural features, beinghole type openings in one blade, and in all blades, respectively, inaccordance with some embodiments of the invention;

FIGS. 25A and 25B are schematic perspective views of the rotor 140, withrotor-based performance and process control structural features, beingslit type openings in one blade, and in all blades, respectively, inaccordance with some embodiments of the invention;

FIGS. 26A and 26B are schematic perspective views of the rotor 140, withrotor-based performance and process control structural features, beingteeth or spike type protrusions on the convex side of one blade, and ofall blades, respectively, in accordance with some embodiments of theinvention;

FIGS. 27A and 27B are schematic perspective views of the rotor 140, withrotor-based performance and process control structural features, beingmound type protrusions on the convex side of one blade, and of allblades, respectively, in accordance with some embodiments of theinvention;

FIGS. 28A and 28B are schematic perspective views of the rotor 140, withrotor-based performance and process control structural features, beinginverse mound type depressions in the convex side of one blade, and ofall blades, respectively, in accordance with some embodiments of theinvention;

FIGS. 29A and 29B are schematic perspective views of the rotor 140, withrotor-based performance and process control structural features, beinghole type openings in one sector, and in all sectors, respectively, ofthe reinforcement disc, in accordance with some embodiments of theinvention;

FIGS. 30A and 30B are schematic perspective views of the rotor 140, withrotor-based performance and process control structural features, beingslit type openings in one sector, and in all sectors, respectively, ofthe reinforcement disc, in accordance with some embodiments of theinvention;

FIGS. 31A and 31B are schematic perspective views of the rotor 140, withrotor-based performance and process control structural features, beingteeth or spike type protrusions on the distal face (surface) of onesector, and of all sectors, respectively, of the reinforcement disc, inaccordance with some embodiments of the invention;

FIGS. 32A and 32B are schematic perspective views of the rotor 140, withrotor-based performance and process control structural features, beingteeth or spike type protrusions on the proximal face (surface) of onesector, and of all sectors, respectively, of the reinforcement disc, inaccordance with some embodiments of the invention;

FIGS. 33A and 33B are schematic perspective views of the rotor 140, withrotor-based performance and process control structural features, beingmound type protrusions on the distal face (surface) of one sector, andof all sectors, respectively, of the reinforcement disc, in accordancewith some embodiments of the invention;

FIGS. 34A and 34B are schematic perspective views of the rotor 140, withrotor-based performance and process control structural features, beingmound type protrusions on the proximal face (surface) of one sector, andof all sectors, respectively, of the reinforcement disc, in accordancewith some embodiments of the invention;

FIGS. 35A and 35B are schematic perspective views of the rotor 140, withrotor-based performance and process control structural features, beinginverse mound type depressions in the distal face (surface) of onesector, and of all sectors, respectively, of the reinforcement disc, inaccordance with some embodiments of the invention;

FIGS. 36A and 36B are schematic perspective views of the rotor 140, withrotor-based performance and process control structural features, beinginverse mound type depressions in the proximal face (surface) of onesector, and of all sectors, respectively, of the reinforcement disc, inaccordance with some embodiments of the invention;

FIG. 37 is a schematic diagram of an exemplary application of thechemical reactor, highlighting the chemical reactor operativelyconnected to an exemplary rotor shaft drive unit, in accordance withsome embodiments of the invention; and

FIG. 38 is a schematic diagram of another exemplary application of thechemical reactor, highlighting a catalytic thermal conversion systemthat includes the chemical reactor, in accordance with some embodimentsof the invention.

DESCRIPTION OF SPECIFIC EMBODIMENTS OF THE INVENTION

The present invention, in some embodiments thereof, relates to achemical reactor with high speed rotary mixing, a system thereof, and amethod thereof, for catalytic thermal conversion of organic (i.e.,hydrocarbon-containing) materials (e.g., coal, plastics, rubber, plantmatter, wood shavings, biomass, organic wastes, among various otherpossible organic materials) into diesel and other liquid fuels (e.g.,automobile or/and jet engine fuels). Some embodiments of the presentinvention are particularly relevant to fields of technology that involvenon-conventional commercial scale production of liquid fuel products,and that involve environmentally acceptable commercial scale processingand disposing of organic waste materials.

Implementation of the present invention attempts to address, andovercome, at least some of the on-going problems associated withchemical reactors that include high speed rotary mixing therein forcatalytic thermal conversion of organic materials into diesel and otherliquid fuels.

The present invention, in exemplary embodiments thereof, includes (atleast) the following aspects. A chemical reactor with high speed rotarymixing, for catalytic thermal conversion of organic materials intodiesel and other liquid fuels. A reactor rotary mixing assembly, for usein a chemical reactor with high speed rotary mixing, for catalyticthermal conversion of organic materials into diesel and other liquidfuels. A system for catalytically thermally converting organic materialsinto diesel and other liquid fuels. A method for catalytically thermallyconverting organic materials into diesel and other liquid fuels.

The several aspects of the present invention, in a non-limiting manner,are interrelated, in that illustrative description of characteristicsand technical features of one aspect also relates to, and is fullyapplicable for, illustratively describing characteristics and technicalfeatures of other aspects of the present invention. For example,illustrative description of characteristics and technical features ofthe chemical reactor with high speed rotary mixing, for catalyticthermal conversion of organic materials into diesel and other liquidfuels, or of a component (e.g., reactor rotary mixing assembly) of thechemical reactor, also relates to, and is fully applicable for,illustratively describing characteristics and technical features of oneor more other aspects of the present invention, for example, one or moreaspects about a system for catalytically thermally converting organicmaterials into diesel and other liquid fuels, and one or more aspectsabout a method for catalytically thermally converting organic materialsinto diesel and other liquid fuels.

Additionally, for example, in a non-limiting manner, embodiments of thechemical reactor with high speed rotary mixing, for catalytic thermalconversion of organic materials into diesel and other liquid fuels, orof a component (e.g., reactor rotary mixing assembly) of the chemicalreactor, are suitable for implementing embodiments of a system forcatalytically thermally converting organic materials into diesel andother liquid fuels, and for implementing embodiments of a method forcatalytically thermally converting organic materials into diesel andother liquid fuels.

The chemical reactor with high speed rotary mixing, for catalyticthermal conversion of organic materials into diesel and other liquidfuels, in a non-limiting manner, and in some embodiments, includes: areactor stationary assembly (RSA), configured with only stationarycomponents that remain stationary during operation of the chemicalreactor, and a reactor rotary mixing assembly (RRMA), configured withonly rotatable components that rotate during operation of the chemicalreactor.

In exemplary embodiments, the reactor rotary mixing assembly (RRMA) ofthe chemical reactor, in a non-limiting manner, may be considered as anindividual ‘stand-alone’ apparatus, particularly, based on itsstructural and functional/operational characteristics and features, andalso based on the manner in which it is illustratively described herein.Such an individual ‘stand-alone’ (structural and functional/operational)apparatus corresponds to a particular ‘sub-combination’ of the (overall)chemical reactor with high speed rotary mixing, for catalytic thermalconversion of organic materials into diesel and other liquid fuels,which, in turn, corresponds to another aspect of the present invention.

The system for catalytically thermally converting organic materials intodiesel and other liquid fuels, in a non-limiting manner, and in someembodiments, includes: a chemical reactor that includes a reactorstationary assembly (RSA), configured with only stationary componentsthat remain stationary during operation of the chemical reactor, and areactor rotary mixing assembly (RRMA), configured with only rotatablecomponents that rotate during operation of the chemical reactor; a rotorshaft drive unit, operatively connected to the reactor rotary mixingassembly (RRMA), and configured for driving and rotating the reactorrotary mixing assembly (RRMA) relative to the reactor stationaryassembly (RSA); and catalytic conversion system process units,operatively connected to the chemical reactor. In exemplary embodiments,the catalytic thermal conversion system additionally includes a processcontrol and data-information processing unit, operatively connected to,and, configured for controlling operation of and processingdata-information associated with, the other units (and componentstherein) of the catalytic thermal conversion system, namely, thechemical reactor, the rotor shaft drive unit, and the catalytic thermalconversion system process units.

The method for catalytically thermally converting organic materials intodiesel and other liquid fuels, in a non-limiting manner, and in someembodiments, includes: providing a chemical reactor that includes areactor stationary assembly (RSA), configured with only stationarycomponents that remain stationary during operation of the chemicalreactor, and a reactor rotary mixing assembly (RRMA), configured withonly rotatable components that rotate during operation of the chemicalreactor; operatively connecting the reactor rotary mixing assembly(RRMA) to a rotor shaft drive unit, so as to drive and rotate thereactor rotary mixing assembly (RRMA) relative to the reactor stationaryassembly (RSA); operatively connecting the chemical reactor to catalyticconversion system process units; and operating the chemical reactor andthe catalytic conversion system process units, so as to thermallyconvert organic materials into diesel and other liquid fuels. Inexemplary embodiments, the method further includes controlling operationof and processing data-information associated with, the chemicalreactor, the rotor shaft drive unit, and the catalytic thermalconversion system process units.

For purposes of further understanding exemplary embodiments of thepresent invention, in the following illustrative description thereof,reference is made to the figures. Throughout the following descriptionand accompanying drawings, same reference numbers refer to sameapparatus components, elements, or features. It is to be understood thatthe invention is not necessarily limited in its application toparticular details of construction or/and arrangement of exemplarydevice, apparatus, or/and system components, or to particular sequentialordering of exemplary method steps or procedures, set forth in thefollowing illustrative description. The invention is capable of havingother exemplary embodiments, or/and of being practiced or carried out invarious alternative ways. Exemplary materials of construction and sizedimensions of components, elements, and structural features, andexemplary operating conditions and parameters in applications, of theherein disclosed chemical reactor are separately provided at the end ofthe Description, so as to preserve coherence and clarity of presentationof the disclosed invention.

Throughout the description and accompanying drawings, physicalorientation (location, position) and directional type terms “proximal”and “distal” are used, in a non-limiting manner, for indicating relativeorientations (locations, positions) and directions. The term “distal”,as used herein, refers to the location, position, or direction of thestated or illustrated object or structural feature (being the hereindisclosed overall chemical reactor, a part thereof, or, one or morecomponents thereof) that is/are ‘farther’ (or away) from othercomponents and structures of a more encompassing chemical processingsystem. The term “proximal”, as used herein, refers to the location,position, or direction of the stated or illustrated object or structuralfeature (being the herein disclosed overall chemical reactor, a partthereof, or, one or more components thereof) that is/are ‘nearer orcloser to’ (or towards) other components and structures of a moreencompassing chemical processing system. With respect to left and rightsides of a printed page, or of a computer display, the terms “proximal”and “distal”, as used herein, in a non-limiting manner, correspond tothe left and right sides, respectively, thereof. It is to be understoodthat ‘symmetrically opposite’ terminology (i.e., “distal” instead of“proximal”, and “proximal” instead of “distal”) can be (consistently)used for fully and properly illustratively describing embodiments of thepresent invention.

Consistent with the preceding usage of the physical orientation anddirectional terms “proximal” and “distal”, the term “longitudinallyextending”, as used herein, refers to the physical extension (spanning)of the referenced component or structural feature along a longitudinalaxis (e.g., a central longitudinal axis) that extends in (and along) theproximal direction and in (and along) the distal direction.

The term “longitudinally directed”, as used herein, refers to thedirection that the referenced component or structural featuretransversely faces along a longitudinal axis (e.g., a centrallongitudinal axis) that extends in (and along) the proximal directionand in (and along) the distal direction. For example, the term“longitudinally directed rotor shaft passageway”, as used herein, refersto a passageway (e.g., a circular opening [hole] in the referencedcomponent) in the direction of, and transversely facing, a longitudinalaxis that extends proximally and distally (consistent with the aboveterminology), so as to facilitate longitudinal passage therethrough of arotor shaft. Additionally, for example, the term “longitudinallydirected face”, as used herein, refers to either of two faces of thereferenced component positioned in the direction of, and transverselyfacing, a longitudinal axis that extends proximally and distally(consistent with the above terminology).

Additionally, in the description and accompanying drawings, duringoperation of the chemical reactor (and inside the chemical reactionchamber thereof), the intended direction of rotation of the rotor shaft(and of the rotor fixedly connected thereto, and of the other selectedcomponents [i.e., of the reactor rotary mixing assembly (RRMA)] of thechemical reactor that also rotate, is ‘clockwise’. In the figures, such‘clockwise’ rotation is indicated as, and referred to by, the referenceletter R alongside a curved arrow pointing in the ‘clockwise’ direction.

Referring now to the drawings, FIGS. 1, and 2A-2B, are schematic partlycut-away side, and perspective, views, respectively, of an exemplaryembodiment of the chemical reactor [indicated as, and referred to by,reference number 100] with high speed rotary mixing, for catalyticconversion of organic materials into diesel and other liquid fuels. FIG.3 is a schematic exploded perspective views of exemplary embodiments ofthe chemical reactor 100, and of both the reactor stationary assembly(RSA) 102 and the reactor rotary mixing assembly (RRMA) 104, andcomponents thereof, along with highlighting those components which formand define the chemical reaction chamber 165. FIGS. 4 and 5 areschematic exploded perspective views of an exemplary embodiment of thereactor stationary assembly (RSA) 102, and of the reactor rotary mixingassembly (RRMA) 104, respectively, and components thereof, of thechemical reactor 100. FIGS. 6, 7, and 8 are schematic side, perspective,and distal front cut-away, views, respectively, of exemplary embodimentsof the chemical reactor 100, highlighting latitudinal (transverse)offset λ of indicated chemical reactor components. FIGS. 9 through 36are different schematic views of exemplary embodiments of the severalcomponents (and structural features thereof) of the chemical reactor 100with high speed rotary mixing, for catalytic conversion of organicmaterials into diesel and other liquid fuels.

FIG. 37 is a schematic diagram of an exemplary application of thechemical reactor 100, highlighting the chemical reactor 100 operativelyconnected to an exemplary rotor shaft drive unit. FIG. 38 is a schematicdiagram of another exemplary application of the chemical reactor 100,highlighting a catalytic thermal conversion system that includes thechemical reactor 100.

With reference to FIGS. 1 through 5, in exemplary embodiments, thechemical reactor 100 with high speed rotary mixing, for catalyticthermal conversion of organic materials into diesel and other liquidfuels, includes: a reactor stationary assembly (RSA) 102 and a reactorrotary mixing assembly (RRMA) 104. The chemical reactor 100 is astructural (mechanical) and functional (operational) integratedcombination of the two kinds of assemblies, namely, the reactorstationary assembly (RSA) 102 and the reactor rotary mixing assembly(RRMA) 104, and respective components of each assembly. In addition toFIGS. 1, 2A, 2B, particular illustration of this structural (mechanical)and functional (operational) integrated combination is provided by FIG.3, wherein components of both assemblies are shown (via an explodedview) in their functional (operational) positions (as they are locatedin the chemical reactor 100 [shown in FIGS. 1, 2A, 2B]) relative to eachother, and wherein components of the reactor stationary assembly (RSA)102 are referenced in the lower portion of the figure, while componentsof the reactor rotary mixing assembly (RRMA) 104 are referenced in theupper portion of the figure. FIG. 3 also highlights (indicated by thedotted lines and arrows) the chemical reaction chamber 115, beingspatially defined by the space (volume) formed and bounded by selectedcomponents of the reactor stationary assembly (RSA) 102, and by selectedcomponents of the reactor rotary mixing assembly (RRMA) 104 contained inthat space (volume). The chemical reaction chamber 115 corresponds tothe actual (effective) portion of the overall chemical reactor 100wherein take place the numerous (chemical reaction related)physicochemical processes of mass and heat transfer, mixing,degradation, and catalytic chemical conversion, during operation of thechemical reactor 100.

Reactor Stationary Assembly (RSA)

The reactor stationary assembly (RSA) 102 is configured with onlystationary components that remain stationary (i.e., relative tocomponents of the reactor rotary mixing assembly (RRMA) 104) duringoperation of the chemical reactor 100, and includes the followingcomponents: a reactor central housing 110; proximal and distal reactorinput/output manifolds 112 and 114, respectively; proximal and distalmanifold housings 116 and 118, respectively; proximal and distal dynamicseal housings 120 and 122, respectively; and proximal and distallubricated cartridge seal housings 124 and 126, respectively. Inexemplary embodiments, the reactor stationary assembly (RSA) 102 isadditionally configured with an anti-abrasion shield 128.

The reactor central housing 110 is configured as a tubular memberlongitudinally extending proximally and distally, and having a middleportion with proximal and distal circular open ends.

The proximal and distal reactor input/output manifolds 112 and 114,respectively, are each configured with a longitudinally directed rotorshaft passageway (e.g., a circular opening [hole] that facilitateslongitudinal passage therethrough of the rotor shaft 152). The proximaland distal reactor input/output manifolds 112 and 114, respectively,have a respective distal or proximal circular face that covers, and issealed to, the respective reactor central housing 110 proximal or distalcircular open end. The proximal and distal reactor input/outputmanifolds 112 and 114, respectively, are each housed in a respectiveproximal or distal manifold housing 116 or 118 that has proximal anddistal circular faces and is configured with a longitudinally directedrotor shaft passageway (e.g., a circular opening [hole] that facilitateslongitudinal passage therethrough of the rotor shaft 152). The proximaland distal manifold housings 116 and 118, respectively, with therespective proximal and distal reactor input/output manifolds 112 and114 housed therein, are oppositely located and parallel to each otherwith the reactor central housing 110 longitudinally extendingtherebetween.

The proximal and distal dynamic seal housings 120 and 122, respectively,are each configured with a longitudinally directed rotor shaftpassageway (e.g., a circular opening [hole] that facilitateslongitudinal passage therethrough of the rotor shaft 152). The proximaland distal dynamic seal housings 120 and 122, respectively, have arespective distal or proximal circular face that covers, and is sealedto, the respective proximal or distal circular face of the respectiveproximal or distal manifold housing 116 or 118. The proximal and distaldynamic seal housings 120 and 122, respectively, are located oppositeand parallel to each other relative to the reactor central housing 110.

The proximal and distal lubricated cartridge seal housings 124 and 126,respectively, are each configured with a longitudinally directed rotorshaft passageway (e.g., a circular opening [hole] that facilitateslongitudinal passage therethrough of the rotor shaft 152). The proximaland distal lubricated cartridge seal housings 124 and 126, respectively,have a respective distal or proximal circular face that covers, and issealed to, the respective proximal or distal circular face of therespective proximal or distal dynamic seal housing 120 or 122. Theproximal and distal lubricated cartridge seal housings 124 and 126,respectively, are each configured with a longitudinally directed rotorshaft passageway (e.g., a circular opening [hole] that facilitateslongitudinal passage therethrough of the rotor shaft 152). The proximaland distal lubricated cartridge seal housings 124 and 126, respectively,are located opposite and parallel to each other relative to the reactorcentral housing 110.

The anti-abrasion shield 128 is configured as a tubular memberlongitudinally extending proximally and distally inside of the reactorcentral housing 110, and having a body with proximal and distal circularopen ends, respectively. The proximal circular open end is covered by,fixedly connected (attached) and sealed to, the distal circular face ofthe proximal reactor input/output manifold 112. The distal circular openend is covered by, fixedly connected (attached) and sealed to, theproximal circular face of the distal reactor input/output manifold 114.

Reactor Rotary Mixing Assembly (RRMA)

The reactor rotary mixing assembly (RRMA) 104 is configured with onlyrotatable components that rotate (i.e., relative to components of thereactor stationary assembly (RSA) 102) during operation of the chemicalreactor 100, and includes the following components: a rotor 140;proximal and distal rotatable dynamic seals 144 and 146, respectively;proximal and distal rotatable lubricated cartridge seals 148 and 150,respectively; and a rotatable rotor shaft 152. In exemplary embodiments,the rotary mixing assembly (RRMA) 104 is additionally configured withproximal and distal rotatable cartridge bearings 154 and 156,respectively. In exemplary embodiments, the rotary mixing assembly(RRMA) 104 is additionally configured with one proximal rotatable pairedset 158 a, and with two distal rotatable paired sets 158 b and 158 c, ofa locknut 160 and a locknut washer 162.

The rotor 140 is housed inside of the reactor central housing 110, andis configured with a rotor tubular portion and a plurality of equallyconfigured (shaped and sized) radially curved rotor blades that radiallyextend from, and longitudinally along, the outer circumferentialperiphery of the rotor tubular portion. The rotor tubular portionlongitudinally extends proximally and distally, and has proximal anddistal circular open ends, so as to form a longitudinally directed rotorshaft passageway (a circular opening) that facilitates longitudinalpassage therethrough of the rotor shaft 152. The rotor 140 is fixedlymounted on (connected, attached to), via the rotor tubular portion, therotatable rotor shaft 152 so as to facilitate controllable rotation ofthe rotor 140 during operation of the chemical reactor 100.

In exemplary embodiments, the rotor 140 includes a rotor centralreinforcement disc. The rotor central reinforcement disc has proximaland distal circular faces, and a central opening concentric with thecircumferential periphery of the rotor tubular portion, therebyfacilitating longitudinal passage therethrough of the rotor shaft 152.The rotor central reinforcement disc transversely bisects (divides intotwo equal portions) the longitudinal lengths of the rotor blades, andthe outer circumferential periphery of the rotor central reinforcementdisc is transverse to, and coincides with, the radial outer ends of therotor blades.

As illustratively described below along with reference to FIGS. 24-36,in exemplary embodiments of the chemical reactor 100, in general, and ofthe rotor 140, in particular, the rotor 140 is configured with at leastone rotor-based performance and process control structural featureselected from the group consisting of: openings (e.g., holes or slits),protrusions (e.g., teeth or spikes, or mounds), and depressions (e.g.,inverse mounds). In such exemplary embodiments, at least one of therotor blades 180 is configured with one or more of the rotor-basedperformance and process control structural features. In exemplaryembodiments wherein the rotor 140 includes the rotor centralreinforcement disc 190, optionally, alternatively, or additionally, atleast a portion of the rotor central reinforcement disc 190 isconfigured with one or more of the rotor-based performance and processcontrol structural features. In such exemplary embodiments, therotor-based performance and process control structural featuresfacilitate ‘fine-tuning’ type additional controlling performance of therotor 140, in particular, and of the chemical reactor 100, in general,so as to provide an additional layer or level of control of the numerous(chemical reaction related) physicochemical processes of mass and heattransfer, mixing, degradation, and catalytic chemical conversion, takingplace inside of the reactor central housing 110 (i.e., inside of thechemical reaction chamber 115 therein) during operation of the chemicalreactor 100.

The proximal and distal rotatable dynamic seals 144 and 146,respectively, are each configured with a longitudinally directed rotorshaft passageway (e.g., a circular opening [hole] that facilitateslongitudinal passage therethrough of the rotor shaft 152), and are eachhoused inside of the respective proximal or distal dynamic seal housing120 or 122.

The proximal and distal rotatable lubricated cartridge seals 148 and 150are each configured with a longitudinally directed rotor shaftpassageway (e.g., a circular opening [hole] that facilitateslongitudinal passage therethrough of the rotor shaft 152), and are eachhoused in the respective proximal or distal lubricated cartridge sealhousing 124 or 126.

The rotatable rotor shaft 152 is longitudinally supported via theproximal and distal lubricated cartridge seal housings 124 and 126,respectively, and longitudinally passes through the reactor centralhousing 110 proximal and distal circular open ends, and through therotor shaft passageways of the following components: the rotor 152, theproximal and distal reactor input/output manifolds 112 and 114,respectively; the proximal and distal manifold housings 116 and 118,respectively; the proximal and distal rotatable dynamic seals 144 and146, respectively; the proximal and distal dynamic seal housings 120 and122, respectively; the proximal and distal rotatable lubricatedcartridge seals 148 and 150, respectively; and the proximal and distallubricated seal housings 124 and 126, respectively. In exemplaryembodiments wherein the reactor stationary assembly (RSA) 102additionally includes the anti-abrasion shield 128, the rotor shaft 152also longitudinally passes therethrough. In exemplary embodimentswherein the reactor rotary mixing assembly (RRMA) 104 additionallyincludes the proximal and distal rotatable cartridge bearings 154 and156, respectively, or/and, additionally includes at least one rotatablepaired set 158 of a locknut 160 and a locknut washer 162, the rotorshaft 152 also longitudinally passes through these components.

The rotor shaft 152 is fixedly connected (attached) to the rotor tubularportion so as to facilitate controllable rotation of the rotor 140inside the chemical reaction chamber 115 during operation of thechemical reactor 100. The rotor shaft 152 includes several reactorrotary mixing assembly (RRMA) component mounting (connecting, attaching)and fixing portions or sections (for example, grooves, slots, slits,recesses, depressions, and the like) located at several places along thelongitudinal length of the rotor shaft 152, which are configured formounting (connecting, attaching) and fixing all the components of thereactor rotary mixing assembly (RRMA) 104 that rotate during operationof the chemical reactor 100. Thus, the reactor rotary mixing assembly(RRMA) component mounting and fixing portions or sections are configuredfor fixedly mounting (connecting, attaching) upon the rotor shaft 152all components of the reactor rotary mixing assembly (RRMA) 104, namely,the rotor 140; the proximal and distal rotatable dynamic seals 144 and146, respectively; and the proximal and distal rotatable lubricatedcartridge seals 148 and 150, respectively.

In exemplary embodiments wherein the reactor rotary mixing assembly(RRMA) 104 additionally includes the proximal and distal rotatablecartridge bearings 154 and 156, respectively, or/and, additionallyincludes at least one rotatable paired set 158 of a locknut 160 and alocknut washer 162, the reactor rotary mixing assembly (RRMA) componentmounting and fixing portions or sections (along the rotor shaft 152) arealso configured for fixedly mounting those additional reactor componentsupon the rotor shaft 152.

The chemical reactor 100, in general, and the rotor shaft 152, inparticular, are operably connectable to a rotor shaft drive unit (forexample, rotor shaft drive unit 300 shown in FIGS. 37 and 38, andfurther described hereinbelow) that is configured for driving (powering)and rotating the rotor shaft 152. Such operable connection between therotor shaft 152 and a rotor shaft drive unit is facilitated by the rotorshaft 152 additionally including a rotor shaft drive unit connecting andfixing portion that is located along the distal end portion of the rotorshaft 152.

In exemplary embodiments of the chemical reactor 100, the reactor rotarymixing assembly (RRMA) 104 additionally includes a proximal rotatablecartridge bearing 154, that is configured with a longitudinally directedrotor shaft passageways (e.g., a circular opening [hole] thatfacilitates longitudinal passage therethrough of the rotor shaft 152),and has a distal circular face that covers, and is sealed to, theproximal circular face of the proximal rotatable lubricated cartridgeseal 148. In exemplary embodiments, the proximal rotatable cartridgebearing 154 is configured as a ‘non-locating’ type of cartridge bearing,that provides ‘radial’ support to the rotor shaft 152.

In exemplary embodiments of the chemical reactor 100, the reactor rotarymixing assembly (RRMA) 104 additionally includes a distal rotatablecartridge bearing 156, that is configured with a longitudinally directedrotor shaft passageway (e.g., a circular opening [hole] that facilitateslongitudinal passage therethrough of the rotor shaft 152), and has aproximal circular face that covers, and is sealed to, the distalcircular face of the distal rotatable lubricated cartridge seal 150. Inexemplary embodiments, the distal rotatable cartridge bearing 156 isconfigured as a ‘locating’ type of cartridge bearing, that provides both‘radial’ support and (proximal-distal) ‘longitudinal’ guidance to therotor shaft 152.

In exemplary embodiments of the chemical reactor 100, the reactor rotarymixing assembly (RRMA) 104 additionally includes at least one rotatablepaired set 158 of a locknut 160 and a locknut washer 162, located at oneor more respective positions on the rotor shaft 152. FIG. 5 shows anexploded perspective view of such an exemplary embodiment, correspondingto one proximal rotatable paired set 158 a, and two distal rotatablepaired sets 158 b and 158 c, of the locknut 160 and the locknut washer162.

Chemical Reaction Chamber

The chemical reaction chamber 115 corresponds to the actual (effective)portion of the overall chemical reactor 100 wherein take place thenumerous (chemical reaction related) physicochemical processes of massand heat transfer, mixing, degradation, and catalytic chemicalconversion, during operation of the chemical reactor 100. For example,as shown in FIG. 3, and indicated therein by the dotted lines andarrows, the chemical reaction chamber 115 is spatially defined as thespace (volume) formed and bounded (exclusively and only) by: (i)selected components of the reactor stationary assembly (RSA) 102 and(ii) selected components of the reactor rotary mixing assembly (RRMA)104 contained in (i.e., occupying part of) the space (volume) of (i).

Specifically, in exemplary embodiments, the chemical reaction chamber115 is defined as the space (volume) formed and bounded (exclusively andonly) by: (i) the distal and proximal faces of the respective proximaland distal reactor input/output manifolds 112 and 114, that are fixedlyconnected (attached) and sealed to the respective proximal and distalopen ends of the reactor central housing 110, and (ii) the presence ofthe rotor 140, fixedly mounted on the rotor shaft 152, of the reactorrotary mixing assembly (RRMA) 104, contained in (occupying part of) thespace (volume) of (i).

In exemplary embodiments wherein the reactor stationary assembly (RSA)102 is additionally configured with the anti-abrasion shield 128, then,the chemical reaction chamber 115 is defined as the space (volume)formed and bounded (exclusively and only) by: (i) the distal andproximal faces of the respective proximal and distal reactorinput/output manifolds 112 and 114, that are fixedly connected(attached) and sealed to the respective proximal and distal open ends ofthe anti-abrasion shield 128, and (ii) the presence of the rotor 140,fixedly mounted on the rotor shaft 152, of the reactor rotary mixingassembly (RRMA) 104, contained in (occupying part of) the space (volume)of (i).

Latitudinal or Radial (Transverse) Offset of Chemical Reactor Components

The chemical reactor 100 is configured based on principles, notidentical, but similar to, those of a liquid-ring (centrifugal) pump.Structure and function (operation) of the chemical reactor 100 (andcomponents therein) are based on and involve relative differentialpositioning and functioning of ‘all’ chemical reactor components (i.e.,of the reactor stationary assembly (RSA) 102) and of the reactor rotarymixing assembly (RRMA) 104), and not only of two chemical reactorcomponents (e.g., the rotor 140 and the reactor central housing 110).

The chemical reactor 100 is configured with a ‘latitudinal or radialeccentricity’, wherein a first sub-set of reactor components arepositioned, and have geometrical centers, latitudinally or radiallyeccentric relative to the positioning and geometrical centers of asecond sub-set of reactor components. Herein, such ‘latitudinal orradial eccentricity’ of the chemical reactor 100 is also referred to as‘latitudinal or radial (transverse) offset’, wherein the chemicalreactor 100 is configured with a ‘latitudinal or radial (transverse)offset’ of a first sub-set of reactor components relative to a secondsub-set of reactor components.

The term ‘latitudinal or radial (transverse) offset’, or, more briefly,‘latitudinal or radial offset’, as used herein, refers to the offsetdefined by the distance or length that latitudinally or radially (i.e.,transversely) extends in between two parallel proximal-distal centrallongitudinal axes of a first sub-set of reactor components and a secondsub-set of reactor components. Alternatively stated, the ‘latitudinal orradial (transverse) offset’ refers to, and is defined by, thelatitudinal or radial distance or length that transversely extendsbetween a first proximal-distal central longitudinal axis that passesthrough the geometrical center points of the first sub-set of reactorcomponents and a second proximal-distal central longitudinal axis thatpasses through the geometrical center points of the second sub-set ofreactor components.

FIGS. 6 and 7 are schematic side and perspective views, respectively, ofthe chemical reactor 100, highlighting the latitudinal or radial(transverse) offset of the indicated chemical reactor components, withrespect to (proximal-distal) longitudinal axes. The ‘latitudinal orradial (transverse) offset’ is indicated as, and referred to by, thereference symbol 2.

In exemplary embodiments, the first sub-set of reactor componentsincludes: (i) the rotor 140 (of the RRMA 104); (ii) the rotatable rotorshaft 152 (of the RRMA 104); (iii) the proximal and distal rotatabledynamic seals 144 and 146, respectively (of the RRMA 104); (iv) theproximal and distal dynamic seal housings 120 and 122, respectively (ofthe RSA 102); (v) the proximal and distal rotatable lubricated cartridgeseals 148 and 150, respectively (of the RRMA 104); (vi) the proximal anddistal lubricated cartridge seal housings 124 and 126, respectively (ofthe RSA 102); and (vii) the proximal and distal rotatable cartridgebearings 154 and 156, respectively (of the RRMA 104).

The first sub-set of reactor components (i)-(vii) is characterized by afirst central longitudinal axis (as indicated in FIGS. 6 and 7 by thedashed line with reference symbol X1) that longitudinally (proximally todistally) passes through the geometrical center points of each of thereactor components (i)-(vii).

In exemplary embodiments, the second sub-set of reactor componentsincludes: (viii) the reactor central housing 110 (of the RSA 102); (ix)the proximal and distal reactor input/output manifolds 112 and 114,respectively (of the RSA 102); (x) the proximal and distal manifoldhousings 116 and 118, respectively (of the RSA 102); and, if present inthe chemical reactor 100, (xi) the anti-abrasion shield 128 (of the RSA102).

The second sub-set of reactor components (viii)-(xi) is characterized bya second central longitudinal axis (as indicated in FIGS. 6 and 7 by thedotted line with reference symbol X2) that longitudinally (proximally todistally) passes through the geometrical center points of each of thereactor components (viii)-(xi).

Accordingly, in exemplary embodiments, the chemical reactor 100 isconfigured with a latitudinal or radial (transverse) offset λ of a firstsub-set of reactor components (i)-(vii) relative to a second sub-set ofreactor components (viii)-(xi). More specifically, in exemplaryembodiments, the chemical reactor 100 is configured with a latitudinalor radial (transverse) offset λ, whereby the first sub-set of reactorcomponents (i)-(vii) has a first central longitudinal axis X1 that islatitudinally or radially (transversely) offset relative to a secondcentral longitudinal axis X2 of the second sub-set of reactor components(viii)-(xi).

Another view of the above described latitudinal or radial (transverse)offset λ of reactor components is provided in FIG. 8, being a schematicdistal front cut-away view of the chemical reactor 100, highlighting thelatitudinal or radial (transverse) offset λ of the chemical reactorcomponents, with respect to transverse axes. The view shown in FIG. 8 istransverse (perpendicular) to the view shown in FIG. 6. Accordingly, asshown in FIG. 8, in exemplary embodiments, the chemical reactor 100 isconfigured with a latitudinal or radial (transverse) offset λ, wherebythe first sub-set of reactor components (i)-(vii) has a first centraltransverse axis Y1 that is latitudinally or radially (transversely)offset relative to a second central transverse axis Y2 of the secondsub-set of reactor components (viii)-(xi).

The chemical reactor 100, with the latitudinal or radial (transverse)offset λ of the first sub-set of reactor components (i)-(vii) relativeto the second sub-set of reactor components (viii)-(xi), operates asfollows, with particular reference made to FIG. 8. Rotation of the rotorshaft 152 drives rotation of the reactor rotary mixing assembly (RRMA)104, which, in turn, drives rotation of the rotor 140 inside thechemical reaction chamber 115. Rotary motion of the rotor 140, viacentrifugal forces, centrifugally propels and forces liquid in thechemical reaction chamber 115 onto the tubular inner surface of thereactor central housing 110 (or, if present, onto the tubular innersurface of the anti-abrasion shield 128). The propelled liquid forms aliquid ring along the tubular inner surface of the reactor centralhousing 110 or the anti-abrasion shield 128. The liquid ring acts as asealant along the tubular inner surface of the reactor central housing110 (or of the anti-abrasion shield 128) which prevents, or at leastminimizes, gases from escaping the chemical reaction chamber 115,translating to high efficiency and performance of the chemical reactor100.

As a result of the latitudinal or radial (transverse) offset λ existingbetween the first and second sub-set of reactor components, rotarymotion of the rotor 140 and the rotor blades thereof generate a pressuregradient circumferentially along the tubular inner surface of thereactor central housing 110 (or of the anti-abrasion shield 128),thereby producing pressure differentials at different locations alongthe reactor central housing (or anti-abrasion shield) tubular innersurface. By way of such pressure differentials, chemical reactor inputmaterial (containing a mixture of solids, liquids, and gases) is input(sucked), via the input ports 202 of the reactor input/output manifolds112 and 114, into the chemical reaction chamber 115. Continuous rotarymotion of the rotor 140 then drives the numerous (chemical reactionrelated) physicochemical processes of mass and heat transfer, mixing,degradation, and catalytic chemical conversion, taking place inside thechemical reaction chamber 115. Also, by way of the pressuredifferentials, along with the rotating rotor blades compressing chemicalreaction material along the reactor central housing (or anti-abrasionshield) tubular inner surface, chemical reactor output material(containing a mixture of solids, liquids, and gases) is output(discharged), via the output ports 206 of the reactor input/outputmanifolds 112 and 114, from the chemical reaction chamber 115.

Additional Views, Characteristics, and Features of Components of theReactor Stationary Assembly (RSA) and of the Reactor Rotary MixingAssembly (RRMA)

FIGS. 9 through 23 are additional schematic views of exemplaryembodiments of the several components (and features thereof) of thechemical reactor 100 with high speed rotary mixing, for catalyticconversion of organic materials into diesel and other liquid fuels.

Reactor Stationary Assembly (RSA)

The reactor stationary assembly (RSA) 102 is configured with onlystationary components that remain stationary (i.e., relative tocomponents of the reactor rotary mixing assembly (RRMA) 104) duringoperation of the chemical reactor 100, and includes: a reactor centralhousing 110; proximal and distal reactor input/output manifolds 112 and114, respectively; proximal and distal manifold housings 116 and 118,respectively; proximal and distal dynamic seal housings 120 and 122,respectively; and proximal and distal lubricated cartridge seal housings124 and 126, respectively. In exemplary embodiments, the reactorstationary assembly (RSA) 102 is additionally configured with ananti-abrasion shield 128.

Reactor Central Housing

FIGS. 9A and 9B are schematic perspective and side views, respectively,of an exemplary embodiment of the reactor central housing 110 (part ofthe reactor stationary assembly (RSA) 102). The reactor central housing110 is structured and functions as the (geometrical) central component(body, member) of the overall chemical reactor 100, that houses, and isfixedly connected (attached) to, other components of the chemicalreactor 100.

The reactor central housing 110 is configured as a tubular memberlongitudinally extending proximally and distally, and having a middleportion 110 a with proximal and distal circular open ends 110 b and 110c, respectively. In exemplary embodiments, the proximal and distalcircular open ends 110 b and 110 c, respectively, are flanged andinclude circumferentially positioned bolt holes, for facilitatingcovering of, and sealing to, the proximal and distal open ends 110 b and110 c by corresponding distal and proximal circular open faces of theproximal and distal reactor input/output manifolds 112 and 114,respectively. In exemplary embodiments, the reactor central housing 110is additionally configured with supporting and fixing members (forexample, supporting and fixing members 110 d) that extend from bottomportions of the proximal and distal open ends 110 b and 110 c,respectively. The supporting and fixing members 110 d are configured forsupporting and fixing the reactor central housing 110, in particular,and the overall chemical reactor 100, in general, to a stable and levelstructure, such as the floor or ground.

In exemplary embodiments of the chemical reactor, the reactor stationaryassembly (RSA) 102 is additionally configured with an anti-abrasionshield (for example, anti-abrasion shield 128) thatphysically/mechanically shields the tubular inner surface 110 e of thereactor central housing 110 from abrasion (i.e., physical or/andchemical ‘wear and tear’) during operation of the chemical reactor 100.In exemplary embodiments, the anti-abrasion shield 128 is fixedlyconnected (attached) to the inside (i.e., the tubular inner surface 110e) of the middle portion 110 a of the reactor central housing 110. Inexemplary embodiments, the anti-abrasion shield 128 is configured withat least one fixing element (for example, in FIGS. 16A-16C, two fixingelements 230) which facilitate fixedly connecting (attaching) theanti-abrasion shield 128 to the inner surface 110 e of the reactorcentral housing middle portion 110 a. In exemplary embodiments, theanti-abrasion shield fixing elements 230 are configured as small(circular or elliptical) protrusions that protrude (extend, jut out, orproject) from the tubular outer peripheral surface of the anti-abrasionshield 128. Such small protrusions are configured (shaped and sized) soas to securely and fixedly fit into corresponding mating depressions(small hollowed out portions) that are configured in the tubular innersurface 110 e of the reactor central housing middle portion 110 a. InFIG. 9B, exemplary mating depressions (small hollowed out portions)configured in the tubular inner surface 110 e of the reactor centralhousing middle portion 110 a are referenced as anti-abrasion shieldfixing points 110 fp, whose exemplary locations are indicated by the twodotted line arrows.

Reactor Input/Output Manifolds, and Manifold Housings

FIGS. 10A and 10B are schematic proximal front and distal front views,respectively, of an exemplary embodiment of the distal reactorinput/output manifold 114 (part of the reactor stationary assembly (RSA)102). FIGS. 11A and 11B are schematic proximal front and distal frontviews, respectively, of an exemplary embodiment of the distal manifoldhousing 118 (part of the reactor stationary assembly (RSA) 102). FIGS.12A and 12B are schematic proximal front and distal front views,respectively, of an exemplary embodiment of the proximal reactorinput/output manifold 112 (part of the reactor stationary assembly (RSA)102). FIGS. 13A and 13B are schematic proximal front and distal frontviews, respectively, of an exemplary embodiment of the proximal manifoldhousing 116 (part of the reactor stationary assembly (RSA) 102).

The distal and proximal reactor input/output manifolds 114 and 112,respectively, aside from being structural mirror images of each other,are identically the same components with the same structural andfunctional features and characteristics, and are located opposite andparallel to each other relative to the reactor central housing 110. Thedistal and proximal reactor input/output manifold housings 118 and 116,respectively, aside from being structural mirror images of each other,are identically the same components with the same structural andfunctional features and characteristics, and are located opposite andparallel to each other relative to the reactor central housing 110. Thereactor input/output manifolds 114 and 112 are structured and functionfor: (i) facilitating input of materials into the chemical reactor 100,and (ii) facilitating output of materials from the chemical reactor 100.The manifold housings 118 and 116 are structured and function for firmlysupporting and holding (housing) the respective reactor input/outputmanifolds 114 and 112.

Each of the distal and proximal reactor input/output manifolds 114 and112, respectively, is configured with a manifold input (suction) port202, a manifold input aperture 204, a manifold output (discharge) port206, a manifold output aperture 208, a manifold drain port 210, amanifold drain aperture 212, and a longitudinally directed rotor shaftpassageway (e.g., a circular opening) 200 that facilitates longitudinalpassage therethrough of the rotor shaft 152.

In exemplary embodiments, each of the distal and proximal reactorinput/output manifolds 114 and 112, respectively, is configured with acircular base 114 a and 112 a, respectively, that has two longitudinallydirected distal and proximal circular faces. Each of the distal face ofthe distal reactor input/output manifold 114, and the proximal face ofthe proximal reactor input/output manifold 112, is configured thereuponwith the manifold input (suction) port 202, the manifold output(discharge) port 206, and the manifold drain port 210, for example, asparticularly shown in FIGS. 10B and 12A. Each of the proximal face ofthe distal reactor input/output manifold 114, and the distal face of theproximal reactor input/output manifold 112, is configured with themanifold input aperture 204, the manifold output aperture 208, and themanifold drain aperture 212, which are in fluid communication with thecorresponding manifold input (suction) port 202, manifold output(discharge) port 206, and manifold drain port 210, respectively, forexample, as particularly shown in FIGS. 10A and 12B.

Each of the distal and proximal manifold housings 118 and 116,respectively, is configured with correspondingly shaped and sizedchannels that facilitate passage and firm holding of the reactorinput/output manifold input (suction) port 202, output (discharge) port206, and drain port 210. Namely, a manifold input (suction) port channel216, a manifold output (discharge) port channel 218, and a manifolddrain port channel 220, respectively, for example, as particularly shownin FIGS. 11A and 13B. Each of the distal and proximal reactorinput/output manifold housings 118 and 116, respectively, is alsoconfigured with a longitudinally directed rotor shaft passageway (e.g.,a circular opening) 214 that facilitates longitudinal passagetherethrough of the rotor shaft 152.

In exemplary embodiments, each of the distal and proximal manifoldhousings 118 and 116, respectively, is configured with a circular base118 a and 116 a, respectively, that has two longitudinally directeddistal and proximal circular faces. Each of the proximal face of thedistal manifold housing 118, and the distal face of the proximalmanifold housing 116, is configured with the manifold input (suction)port channel 216, the manifold output (discharge) port channel 218, andthe manifold drain port channel 220, respectively, for example, asparticularly shown in FIGS. 11A and 13B. Each of the distal face of thedistal manifold housing 118, and the proximal face of the proximalmanifold housing 116, is configured on the periphery thereof with one ormore annular channels, for example, as particularly shown in FIGS. 11Band 13A, for facilitating direct, immediately adjacent fixed connection(attachment) and sealing to a corresponding proximal or distal face ofthe distal and proximal dynamic seal housings 122 and 120, respectively.

Dynamic Seal Housings

FIGS. 14A and 14B are schematic perspective and side views,respectively, of an exemplary embodiment of the distal dynamic sealhousing 122 (part of the reactor stationary assembly (RSA) 102). FIG.14C is a schematic of the proximal front view of an exemplary embodimentof the proximal dynamic seal housing 120, and also of the distal frontview of the distal dynamic seal housing 122. FIG. 14D is a schematic ofthe distal front view of an exemplary embodiment of the proximal dynamicseal housing 120, and also of the proximal front view of the distaldynamic seal housing 122. The distal and proximal dynamic seal housings122 and 120, respectively, are identically the same components with thesame structural and functional features and characteristics, and arelocated opposite and parallel to each other relative to the reactorcentral housing 110. The dynamic seal housings 122 and 120 arestructured and function for firmly supporting and holding (housing) therespective rotatable dynamic seals 146 and 144.

In exemplary embodiments, each of the distal and proximal dynamic sealhousings 122 and 120, respectively, is configured with a circular base121 that has two longitudinally directed distal and proximal circularfaces. Each of the distal face of the distal dynamic seal housing 122,and the proximal face of the proximal dynamic seal housing 120, isconfigured thereupon with a tubular support member 123 that supports andholds a corresponding proximal or distal face of the distal and proximalrotatable lubricated cartridge seals 150 and 148, respectively. Each ofthe proximal face of the distal dynamic seal housing 122, and the distalface of the proximal dynamic seal housing 120, is configured with asurface 121 s that firmly holds thereupon a respective distal orproximal rotatable dynamic seal 146 or 148. Each of the distal andproximal dynamic seal housings 122 and 120, respectively, is alsoconfigured with a longitudinally directed rotor shaft passageway (e.g.,a circular opening) 222 that facilitates longitudinal passagetherethrough of the rotor shaft 152.

The proximal face of the distal dynamic seal housing 122 is fixedlyconnected (attached) and sealed to the distal face of the distalmanifold housing 118. The distal face of the distal dynamic seal housing122 is fixedly connected (attached) and sealed to the proximal face ofthe distal lubricated cartridge seal housing 126. The distal face of theproximal dynamic seal housing 120 is fixedly connected (attached) andsealed to the proximal face of the proximal manifold housing 116. Theproximal face of the proximal dynamic seal housing 120 is fixedlyconnected (attached) and sealed to the distal face of the proximallubricated cartridge seal housing 124.

Lubricated Cartridge Seal Housings

FIGS. 15A and 15B are schematic perspective and side views,respectively, of an exemplary embodiment of the distal lubricatedcartridge seal housing 126 (part of the reactor stationary assembly(RSA) 102). FIG. 15C is a schematic of the proximal front view of anexemplary embodiment of the proximal lubricated cartridge seal housing124, and also of the distal front view of the distal lubricatedcartridge seal housing 126. FIG. 15D is a schematic of the distal frontview of an exemplary embodiment of the proximal lubricated cartridgeseal housing 124, and also of the proximal front view of the distallubricated cartridge seal housing 126. The distal and proximallubricated cartridge seal housings 126 and 124, respectively, areidentically the same components with the same structural and functionalfeatures and characteristics, and are located opposite and parallel toeach other relative to the reactor central housing 110. The lubricatedcartridge seal housings 126 and 124 are structured and function forfirmly supporting and holding (housing) the respective rotatablelubricated cartridge seals 150 and 148, and for firmly supporting therotor shaft 152.

In exemplary embodiments, each of the distal and proximal lubricatedcartridge seal housings 126 and 124, respectively, is configured with acircular base 125 that has two longitudinally directed distal andproximal circular faces. Each of the distal face of the distallubricated cartridge seal housing 126, and the proximal face of theproximal lubricated cartridge seal housing 124, is configured thereuponwith a seal supporting and holding member 127 that supports and holdsthe body of the distal and proximal rotatable lubricated cartridge seals150 and 148, respectively. In exemplary embodiments, the seal supportingand holding member 127 is configured as a tubular member longitudinallyextending proximally and distally, and having at least two (for example,six) triangular support arms 127 a extending from along the longitudinalwalls of the seal supporting and holding member 127 to the outer surfaceof the corresponding distal or proximal face of the base 125 of therespective distal or proximal lubricated cartridge seal housing 126 and124. Each of the distal and proximal lubricated cartridge seal housings126 and 124, respectively, is also configured with a longitudinallydirected rotor shaft passageway (e.g., a circular opening) 224 thatfacilitates longitudinal passage therethrough of the rotor shaft 152.

The proximal face of the distal lubricated cartridge seal housing 126 isfixedly connected (attached) and sealed to the distal face of the distaldynamic seal housing 122. The distal face of the distal lubricatedcartridge seal housing 126 is fixedly connected (attached) and sealed tothe proximal face of the (locating) distal rotatable cartridge bearing156. The distal face of the proximal lubricated cartridge seal housing124 is fixedly connected (attached) and sealed to the proximal face ofthe proximal dynamic seal housing 120. The proximal face of the proximallubricated cartridge seal housing 124 is fixedly connected (attached)and sealed to the distal face of the (non-locating) proximal rotatablecartridge bearing 154.

Anti-Abrasion Shield

In exemplary embodiments of the chemical reactor, the reactor stationaryassembly (RSA) 102 is additionally configured with an anti-abrasionshield (for example, anti-abrasion shield 128). FIGS. 16A, 16B, and 16Care schematic tilted front, side, and perspective views, respectively,of an exemplary embodiment of the anti-abrasion shield 128 (part of thereactor stationary assembly (RSA) 102). FIG. 8 schematically shows adistal front cut-away view of the anti-abrasion shield 128 relative tothe reactor central housing 110, inside the chemical reaction chamber115. The anti-abrasion shield 128 is structured and functions forphysically/mechanically shielding the tubular inner surface 110 e of thereactor central housing 110 from abrasion (i.e., physical or/andchemical ‘wear and tear’) during operation of the chemical reactor 100.

The anti-abrasion shield 128 is configured as a tubular memberlongitudinally extending proximally and distally inside of the reactorcentral housing 110, and having a body 128 a with proximal and distalcircular open ends 128 b and 128 c, respectively. The proximal circularopen end 128 b is covered by, fixedly connected (attached) and sealedto, the distal circular face of the base 112 a of the proximal reactorinput/output manifold 112. The distal circular open end 128 c is coveredby, fixedly connected (attached) and sealed to, the proximal circularface of the base 112 a of the distal reactor input/output manifold 114.

In exemplary embodiments, the anti-abrasion shield 128 is fixedlyconnected (attached) to the inside (i.e., the tubular inner surface 110e) of the middle portion 110 a of the reactor central housing 110. Inexemplary embodiments, the anti-abrasion shield 128 is configured withat least one fixing element (for example, in FIGS. 16A-16C, two fixingelements 230) which facilitate fixedly connecting (attaching) theanti-abrasion shield 128 to the inner surface 110 e of the reactorcentral housing 110. In exemplary embodiments, the anti-abrasion shieldfixing elements 230 are configured as small (circular or elliptical)protrusions that protrude (extend, jut out, or project) from the tubularouter peripheral surface of the anti-abrasion shield 128. Such smallprotrusions are configured (shaped and sized) so as to securely andfixedly fit into corresponding mating depressions (small hollowed outportions) [for example, in FIG. 9B, indicated as anti-abrasion shieldfixing points 110 fp] that are configured in the tubular inner surface110 e of the reactor central housing 110.

In exemplary embodiments wherein the reactor stationary assembly (RSA)102 is additionally configured with the anti-abrasion shield 128, afterextended operation of the chemical reactor 100, and upon observing thatthe anti-abrasion shield 128 shows signs of extensive abrasion (physicalor/and chemical ‘wear and tear’), there is replacing the used and ‘worn’anti-abrasion shield 128 with a new one, while keeping the same reactorcentral housing 110 in the reactor stationary assembly (RSA) 102 of thechemical reactor 100. Such exemplary embodiments provide the advantageof not needing to replace the reactor central housing 110 after extendedoperation of the chemical reactor 100, during which extensive abrasion(physical or/and chemical ‘wear and tear’) occur during operation of thechemical reactor 100.

Reactor Rotary Mixing Assembly (RRMA)

The reactor rotary mixing assembly (RRMA) 104 is configured with onlyrotatable components that rotate (i.e., relative to components of thereactor stationary assembly (RSA) 102) during operation of the chemicalreactor 100, and includes: a rotor 140; proximal and distal rotatabledynamic seals 144 and 146, respectively; proximal and distal rotatablelubricated cartridge seals 148 and 150, respectively; and a rotatablerotor shaft 152. In exemplary embodiments, the rotary mixing assembly(RRMA) 104 is additionally configured with proximal and distal rotatablecartridge bearings 154 and 156, respectively. In exemplary embodiments,the rotary mixing assembly (RRMA) 104 is additionally configured withone proximal rotatable paired set 158 a, and with two distal rotatablepaired sets 158 b and 158 c, of a locknut 160 and a locknut washer 162.

Rotor

FIGS. 17A and 17B are schematic perspective and side views,respectively, of an exemplary embodiment of the rotor 140 (part of thereactor rotary mixing assembly (RRMA) 104). FIGS. 18A and 18B areschematic perspective and side views, respectively, of an exemplaryembodiment of the rotor 140 (part of the reactor rotary mixing assembly(RRMA) 104), with an exemplary central reinforcement disc 190. The rotor140 is structured and functions for being: (i) a main driver ofinputting (via forced pressure differentials and suction) of materialinto the chemical reactor 100 (chemical reaction chamber 115), (ii) amain driver of outputting (via forced pressure differentials anddischarge) of material from the chemical reactor 100 (chemical reactionchamber 115), (iii) an internal generator of additional heat (producedby forcibly mixing all contents inside the chemical reaction chamber115) that facilitates desired chemical reactions and catalytic chemicalconversion, and (iv) a moving (rotating and impinging) surface uponwhich takes place desired chemical reactions and catalytic chemicalconversion.

The rotor 140 is housed inside of the reactor central housing 110, andis configured with a rotor tubular portion 170 and a plurality ofequally configured (shaped and sized) radially curved rotor blades 180that radially extend from, and longitudinally along, the outercircumferential periphery of the rotor tubular portion 170. The rotortubular portion 170 longitudinally extends proximally and distally, andhas proximal and distal circular open ends, so as to form alongitudinally directed rotor shaft passageway (a circular opening) 172that facilitates longitudinal passage therethrough of the rotor shaft152. The rotor 140 is fixedly mounted on (connected, attached to), viathe rotor tubular portion 170, the rotatable rotor shaft 152, so as tofacilitate controllable rotation of the rotor 140 during operation ofthe chemical reactor 100.

In exemplary embodiments, the rotor 140 is configured without a rotorcentral reinforcement disc 190, for example, as shown in FIGS. 17A and17B. In other exemplary embodiments, the rotor 140 is configured with arotor central reinforcement disc 190, for example, as shown in FIGS. 18Aand 18B, and in several other accompanying figures.

In exemplary embodiments, the rotor central reinforcement disc 190 isconfigured for mechanically reinforcing (strengthening) the rotor 140.The rotor central reinforcement disc 190 has proximal and distalcircular faces, and a central opening concentric with thecircumferential periphery of the rotor tubular portion 170, therebyfacilitating longitudinal passage therethrough of the rotor shaft 152.The rotor central reinforcement disc 190 transversely bisects (dividesinto two equal portions) the longitudinal lengths LL of the rotor blades180, and the outer circumferential periphery of the rotor centralreinforcement disc 190 is transverse to, and coincides with, the radialouter ends of the rotor blades 180. In exemplary embodiments, the rotorcentral reinforcement disc 190 has equally configured (shaped andsized), triangular like, sectors 190 s, wherein each sector 190 s hasdistal and proximal facing sides (surfaces).

Exemplary reference is made to the exemplary rotor 140 shown in FIGS.17A and 17B, whereby the following illustrative description of the rotorblades 180 is equally applicable to the exemplary rotor 140 shown inFIGS. 18A and 18B.

In exemplary embodiments, the rotor 140 is characterized by thestructural features of the rotor tubular portion 170, of the rotorblades 180, and of the rotor central reinforcement disc 190.

In the rotor 140, the rotor tubular portion 170 is characterized by itsinner diameter.

In the rotor 140, the equally configured (shaped and sized) radiallycurved rotor blades 180 are characterized by the structural features of:(i) number of rotor blades, (ii) rotor blade longitudinal length LL,(iii) rotor blade curved radial length CL, (iv) rotor blade thicknessTK, and (v) rotor blade angle of curvature α.

-   -   (i) The number of rotor blades corresponds to the total number        of equally configured (shaped and sized) radially curved rotor        blades 180 that radially extend from, and longitudinally along,        the outer circumferential periphery of the rotor tubular portion        170.    -   (ii) The rotor blade longitudinal length LL corresponds to the        longitudinal (proximal to distal) length of each rotor blade        180.    -   (iii) The rotor blade curved radial length CL corresponds to the        ‘actual’ full radially directed length of each rotor blade 180        in its curved form, that radially extends from the outer        circumferential periphery of the rotor tubular portion 170.    -   (iv) The rotor blade thickness TK corresponds to the (for        example, uniform) thickness of each rotor blade 180        (longitudinally and radially) along the entirety of its curved        form.    -   (v) The rotor blade angle of curvature α corresponds to the        angle formed between a first tangent line t1 that originates        from a point on the outer periphery of the rotor tubular portion        170 and tangentially extends therefrom along the essentially        non-curved and minimally curved portions of the rotor blade 180,        and a second tangent line t2 that originates from a point on the        most curved portion of the rotor blade 180 and tangentially        extends therefrom.

In the rotor 140, the rotor central reinforcement disc 190 ischaracterized by the structural features of: (i) (radially directed)disc diameter, and (ii) (longitudinally directed) disc thickness.

Exemplary embodiments of the rotor 140, wherein at least one of therotor blades 180, or/and the rotor central reinforcement disc 190,is/are configured with at least one rotor-based performance and processcontrol structural feature selected from the group consisting of:openings (e.g., holes or slits), protrusions (e.g., teeth or spikes, ormounds), and depressions (e.g., inverse mounds), are illustrativelydescribed below in the section entitled: Rotor-based performance andprocess control structural features.

Exemplary ranges of size dimensions for each of the above describedstructural features of the rotor 140 are also provided further below.

In exemplary embodiments, during operation of the chemical reactor 100(and inside the chemical reaction chamber 115), the intended directionof rotation of the rotor 140 (when fixedly mounted on (connected,attached to) the rotor shaft 152), and of the other selected components(i.e., of the reactor rotary mixing assembly (RRMA)) of the chemicalreactor that also rotate, is ‘clockwise’, as indicated, for example, inFIGS. 2A, 2B, and 17A, 18A, by the reference letter R alongside thecurved arrow pointing in the ‘clockwise’ direction. According to suchexemplary embodiments, the convex faces (surfaces) of the rotor blades180 are the leading or front faces (surfaces) during the clockwiserotation of the rotor 140, and the concave faces (surfaces) of the rotorblades 180 are the trailing or back faces (surfaces) during theclockwise rotation of the rotor 140. During the clockwise rotation ofthe rotor 140, the convex leading or front faces (surfaces) ‘forcibly’impinge upon, physically (mechanically) engage and interact with, anddrive the contents (i.e., the solid/liquid/vapor/gas mixture) inside thechemical reaction chamber 115.

Rotatable Dynamic Seals

FIGS. 19A and 19B are schematic perspective and side views,respectively, of an exemplary embodiment of the distal rotatable dynamicseal 146 (part of the reactor stationary assembly (RRMA) 104). FIG. 19Cis a schematic of the proximal front view of an exemplary embodiment ofthe proximal rotatable dynamic seal 144, and also of the distal frontview of the distal rotatable dynamic seal 146. FIG. 19D is a schematicof the distal front view of an exemplary embodiment of the proximalrotatable dynamic seal 144, and of the proximal front view of the distalrotatable dynamic seal 146. The distal and proximal rotatable dynamicseals 146 and 144, respectively, are identically the same componentswith the same structural and functional features and characteristics,and are located opposite and parallel to each other relative to thereactor central housing 110.

The rotatable dynamic seals 146 and 144 are structured and function likeimpellers that are rotationally driven by the rotary motion of the rotorshaft 152. During operation of the chemical reactor 100, each of thedistal and proximal rotatable dynamic seals 146 and 144, respectively,rotates and impels (forcibly moves, pumps, transfers) and returnschemical reaction material which escapes or leaks from the chemicalreaction chamber 115, back into the direction of the chemical reactionchamber 115. Accordingly, chemical reaction material that escapes orleaks from the chemical reaction chamber 115 and contacts the rotatabledynamic seals 146 and 144, via action of the rotatable dynamic seals 146and 144 is longitudinally inwardly (i.e., proximally or distally,respectfully) impelled (forcibly moved, pumped, transferred) along theouter surface of the rotor shaft 152, towards and back into thedirection of the chemical reaction chamber 115.

Such action by the rotatable dynamic seals 146 and 144 prevents, or atleast minimizes chemical reaction material that contacts the rotatabledynamic seals 146 and 144, from further moving longitudinally outwardly(i.e., distally or proximally, respectfully) through and past therotatable dynamic seals 146 and 144, towards and into the direction ofthe respective rotatable lubricated cartridge seals 150 and 148. That,in turn, prevents, or at least minimizes, chemical reaction materialfrom contacting and possibly contaminating, and decreasing sealingperformance of, the respective rotatable lubricated cartridge seals 150and 148. In effect, the rotatable dynamic seals 146 and 144 function as‘secondary’ seals, which, together with the respective rotatablelubricated cartridge seals 150 and 148 functioning as ‘primary’ seals,prevent, or at least minimize, chemical reaction material (originatingfrom the chemical reaction chamber 115) that longitudinally outwardlymoves along or/and through the rotor shaft 152, from escaping thechemical reactor 100.

In exemplary embodiments, each of the distal and proximal rotatabledynamic seals 146 and 144, respectively, is configured with a circularbase 145 that has two longitudinally directed distal and proximalcircular faces. Each of the distal face of the distal rotatable dynamicseal 146, and the proximal face of the proximal rotatable dynamic seal144, is configured thereupon with a star fish like member 147. Inexemplary embodiments, the star fish like member 147 has at least two(for example, twelve) curved arms. Each of the proximal face of thedistal rotatable dynamic seal 146, and the distal face of the proximalrotatable dynamic seal 144, is configured with a flat surface 145 s thatfacilitates each of the distal and proximal rotatable dynamic seals 146and 144, respectively, to firmly fit upon, and be held by, the surface121 s of the respective distal or proximal dynamic seal housing 122 or120. Each of the distal and proximal rotatable dynamic seals 146 and144, respectively, is also configured with a longitudinally directedrotor shaft passageway (e.g., a circular opening) 226 that facilitateslongitudinal passage therethrough of the rotor shaft 152.

Rotatable Lubricated Cartridge Seals

FIGS. 20A and 20B are schematic perspective and side views,respectively, of an exemplary embodiment of the distal rotatablelubricated cartridge seal 150 (part of the reactor rotary mixingassembly (RRMA) 104). The distal and proximal rotatable cartridge seals150 and 148, respectively, are identically the same components with thesame structural and functional features and characteristics, and arelocated opposite and parallel to each other relative to the reactorcentral housing 110. Each of the distal and proximal rotatablelubricated cartridge seals 150 and 148, respectively, is housed insidethe seal supporting and holding member 127 of each respective distal andproximal lubricated cartridge seal housing 126 and 124.

The distal and proximal rotatable cartridge seals 150 and 148,respectively, are structured and function to receive, and then,transfer, an externally supplied flow of cool lubricant along the outersurface of the rotor shaft 152, longitudinally inwardly (i.e.,proximally or distally, respectively) towards and into the direction ofthe chemical reaction chamber 115. The rotatable lubricated cartridgeseals 150 and 148 function as ‘primary’ seals, which, together with therespective rotatable dynamic seals 146 and 144 functioning as‘secondary’ seals, prevent, or at least minimize, chemical reactionmaterial (originating from the chemical reaction chamber 115) thatlongitudinally outwardly moves along or/and through the rotor shaft 152,from escaping the chemical reactor 100.

In exemplary embodiments, each of the proximal face of the distalrotatable cartridge seal 150, and the distal face of the proximalrotatable cartridge seal 148, is configured thereupon with a telescopiclike tubular lubricant flow receiver and transfer member 149 a. Thelubricant flow receiver and transfer member 150 a is configured forreceiving a cool lubricant flow (in a range of between about 1-5 litersper hour), from an external source, and transferring the lubricant flowalong the outer surface of the rotor shaft 152, longitudinally inwardly(i.e., proximally or distally, respectively) towards and into thedirection of the chemical reaction chamber 115. In exemplaryembodiments, the lubricant flow receiver and transfer member 149 a isconfigured with a lubricant flow input aperture 149 c that facilitatesreceiving of the externally supplied lubricant flow. In exemplaryembodiments, each of the distal face of the distal rotatable cartridgeseal 150, and the proximal face of the proximal rotatable cartridge seal148, is configured thereupon with a tubular support member 149 b. Thetubular support member 149 b is configured for firmly supporting eachdistal and proximal rotatable lubricated cartridge seal 150 and 148 uponthe rotor shaft 152. Each of the distal and proximal rotatablelubricated cartridge seals 150 and 148, respectively, is also configuredwith a longitudinally directed rotor shaft passageway (e.g., a circularopening) 228 that facilitates longitudinal passage therethrough of therotor shaft 152.

Rotatable Rotor Shaft

FIGS. 21A and 21B are schematic perspective and top views, respectively,of an exemplary embodiment of the rotatable rotor shaft 152 (part of thereactor rotary mixing assembly (RRMA) 104). The rotatable rotor shaft152 is structured and functions as the component (body, member) of theoverall chemical reactor 100 that rotates all the other components ofthe reactor rotary mixing assembly (RRMA) 104 of the chemical reactor100. For doing such, the rotor shaft 152 is structured and functions forsecurely supporting and fixing thereupon, at pre-determined selectedpositions therealong, all the other components of the reactor rotarymixing assembly (RRMA) 104. In exemplary embodiments, the rotor shaft152 is also structured and functions for being operably connectable (forexample, at the distal end portion thereof) to a rotor shaft drive unit(for example, rotor shaft drive unit 300 shown in FIGS. 37 and 38) thatis configured for driving (powering) and rotating the rotor shaft 152,which, in turn, translates to driving and rotating the rotor 140, andthe other components [i.e., of the reactor rotary mixing assembly(RRMA)] of the chemical reactor 100 that also rotate.

The rotatable rotor shaft 152 is longitudinally supported via theproximal and distal lubricated cartridge seal housings 124 and 126,respectively, and longitudinally passes through the reactor centralhousing 110 proximal and distal circular open ends 110 b and 110 c, andthrough the rotor shaft passageways of the following components: therotor 152, the proximal and distal reactor input/output manifolds 112and 114, respectively; the proximal and distal manifold housings 116 and118, respectively; the proximal and distal rotatable dynamic seals 144and 146, respectively; the proximal and distal dynamic seal housings 120and 122, respectively; the proximal and distal rotatable lubricatedcartridge seals 148 and 150, respectively; and the proximal and distallubricated seal housings 124 and 126, respectively.

In exemplary embodiments wherein the reactor stationary assembly (RSA)102 additionally includes the anti-abrasion shield 128, the rotor shaft152 also longitudinally passes through the anti-abrasion shield 128proximal and distal circular open ends 128 b and 128 c, respectively. Inexemplary embodiments wherein the reactor rotary mixing assembly (RRMA)104 additionally includes the proximal and distal rotatable cartridgebearings 154 and 156, respectively, or/and, additionally includes atleast one rotatable paired set 158 of a locknut 160 and a locknut washer162, the rotor shaft 152 also longitudinally passes through thesecomponents.

The rotor shaft 152 is (longitudinally and coaxially) fixedly connected(attached) to the rotor tubular portion 170, so as to facilitatecontrollable rotation of the rotor 140 inside the chemical reactionchamber 115 during operation of the chemical reactor 100. The rotorshaft 152 includes several reactor rotary mixing assembly (RRMA)component mounting (connecting, attaching) and fixing portions orsections (for example, grooves, slots, slits, recesses, depressions, andthe like) located at several places along the longitudinal length of therotor shaft 152, which are configured (shaped and sized) for mounting(connecting, attaching) and fixing all the components of the reactorrotary mixing assembly (RRMA) 104 that rotate during operation of thechemical reactor 100. For example, in FIGS. 21A and 21B, such reactorrotary mixing assembly (RRMA) component mounting and fixing portions orsections are generally indicated, and encompassed, by the bracket withreference number 240. Thus, the reactor rotary mixing assembly (RRMA)component mounting and fixing portions or sections 240 are configured(shaped and sized) for fixedly mounting (connecting, attaching) upon therotor shaft 152 all other components of the reactor rotary mixingassembly (RRMA) 104, namely, the rotor 140; the proximal and distalrotatable dynamic seals 144 and 146, respectively; and the proximal anddistal rotatable lubricated cartridge seals 148 and 150, respectively.For example, the reactor rotary mixing assembly (RRMA) componentmounting and fixing portion or section 240 a is configured for fixedlymounting the rotor 140 (via the inner wall surface of the rotor tubularportion 170) upon the rotor shaft 152.

In exemplary embodiments wherein the reactor rotary mixing assembly(RRMA) 104 additionally includes the proximal and distal rotatablecartridge bearings 154 and 156, respectively, or/and, additionallyincludes at least one rotatable paired set 158 of a locknut 160 and alocknut washer 162, the reactor rotary mixing assembly (RRMA) componentmounting and fixing portions or sections 240 are also configured (shapedand sized) for fixedly mounting those additional reactor components uponthe rotor shaft 152.

In exemplary embodiments, for example, as shown in FIGS. 21A and 21B,the rotor shaft circumferential outer surface is tapered, withdecreasing diameters, at several specific locations along thelongitudinal length of the rotor shaft 152. Such tapering starts fromthe rotor shaft middle portion 152 mp and longitudinally outwardlycontinues towards each of the rotor shaft proximal and distal endportions 152 pep and 152 dep, respectively. A main function of suchlongitudinal tapering of the rotor shaft circumferential outer surfaceis to facilitate optimum, strong, and stable mounting (connecting,attaching) and fixing of the reactor rotary mixing assembly (RRMA) 104components upon and to the rotor shaft 152.

As illustratively described below along with reference to FIGS. 37 and38, in exemplary embodiments, the chemical reactor 100, in general, andthe rotor shaft 152, in particular, are operably connectable to a rotorshaft drive unit 300 that is configured for driving (powering) androtating the rotor shaft 152. Such operable connection is facilitated bythe rotor shaft 152 additionally including a rotor shaft drive unitconnecting and fixing portion, for example, 250, that is located alongthe rotor shaft distal end portion 152 dep, as shown in FIGS. 21A and21B. For example, in such exemplary embodiments, the rotor shaft driveunit connecting and fixing portion 250 is operably connectable to ashaft-to-shaft coupling device, which, in turn, is operably connectableto a motorized drive shaft of the rotor shaft drive unit 300.

Rotatable Cartridge Bearings

In exemplary embodiments, the rotary mixing assembly (RRMA) 104 isadditionally configured with distal and proximal rotatable cartridgebearings 156 and 154, respectively. FIGS. 22A and 22B are schematicperspective and side views, respectively, of an exemplary embodiment ofthe distal rotatable cartridge bearing 156 (part of the reactor rotarymixing assembly (RRMA) 104). The distal and proximal rotatable cartridgebearings 156 and 154, respectively, are the same components with similarstructural and functional features and characteristics, and are locatedopposite and parallel to each other relative to the reactor centralhousing 110. The rotatable cartridge bearings 156 and 154 are structuredand function to provide support and stability to the rotor shaft 152, ina manner which enables the rotor shaft 152 to rotate about itslongitudinal axis with minimal friction.

In exemplary embodiments, the distal rotatable cartridge bearing 156 isconfigured as a ‘locating’ type of cartridge bearing, that provides both‘radial’ support and (proximal-distal) ‘longitudinal’ guidance to therotor shaft 152. In exemplary embodiments, the proximal rotatablecartridge bearing 154 is configured as a ‘non-locating’ type ofcartridge bearing, that provides ‘radial’ support to the rotor shaft152. Aside from the distal-most and proximal-most longitudinal ends ofthe rotor shaft 152, the distal and proximal rotatable cartridgebearings 156 and 154, respectively, are the longitudinally outer mostcomponents of the chemical reactor 100. The proximal face of the(locating) distal cartridge bearing 156 is fixedly connected (attached)and sealed to the distal face of the distal lubricated cartridge sealhousing 126. The distal face of the (non-locating) proximal cartridgebearing 154 is fixedly connected (attached) and sealed to the proximalface of the proximal lubricated cartridge seal housing 124.

In exemplary embodiments, each of the proximal face of the distalrotatable cartridge bearing 156, and the distal face of the proximalrotatable cartridge bearing 154, is configured thereupon with a tubularcartridge 155 a that provides stability to the rotor shaft 152. Inexemplary embodiments, each of the distal face of the distal rotatablecartridge bearing 156, and the proximal face of the proximal rotatablecartridge bearing 154, is configured thereupon with a tubular supportmember 155 b that firmly supports each respective distal and proximalrotatable cartridge bearing 156 and 154 when fixedly mounted on therotor shaft 152. Each of the distal and proximal rotatable cartridgebearings 156 and 154, respectively, is also configured with alongitudinally directed rotor shaft passageway (e.g., a circularopening) 260 that facilitates longitudinal passage therethrough of therotor shaft 152.

In exemplary embodiments, the proximal rotatable cartridge bearing 154is fixedly mounted on the proximal-most longitudinal end of the rotorshaft 152, such that a relatively short length of the proximal-mostlongitudinal end of the rotor shaft 152 proximally extends beyond theproximal face of the proximal rotatable cartridge bearing 154. Inexemplary embodiments, the distal rotatable cartridge bearing 156 isfixedly mounted on the distal-most longitudinal end of the rotor shaft152, such that a relatively moderate length of the distal-mostlongitudinal end of the rotor shaft 152 distally extends beyond thedistal face of the distal rotatable cartridge bearing 154. In suchexemplary embodiments, the relatively moderate length of the rotor shaft152 distal-most longitudinal end that distally extends beyond the distalface of the distal rotatable cartridge bearing 154, corresponds to thedistal end portion 152 dep of the rotor shaft 152 that is configuredwith the rotor shaft drive unit connecting and fixing portion 250 (forexample, as shown in FIGS. 21A and 21B).

Rotatable Paired Sets of a Locknut and a Locknut Washer

In exemplary embodiments of the chemical reactor 100, the reactor rotarymixing assembly (RRMA) 104 additionally includes at least one rotatablepaired set 158 of a locknut 160 and a locknut washer 162. FIG. 23 is aschematic perspective view of an exemplary embodiment of a distalrotatable paired set 158 b of a locknut 160 and a locknut washer 162(part of the reactor rotary mixing assembly (RRMA) 104). The distal andproximal rotatable paired sets 158 a, 158 b, and 158 c, of a locknut 160and a locknut washer 162, for example, as particularly shown in FIGS. 1and 5, are identically the same components with the same structural andfunctional features and characteristics. The rotatable paired sets 158a, 158 b, and 158 c, of the locknut 160 and the locknut washer 162, arestructured and function to additionally facilitate securing and fixingthe positions of components of the reactor rotary mixing assembly (RRMA)104 on and along the rotor shaft 152. In turn, that provides additionalstability to the rotor shaft 152 having thereupon fixedly mountedcomponents of the reactor rotary mixing assembly (RRMA) 104, duringrotation of the rotor shaft 152.

In exemplary embodiments, each of the locknut 160 and the paired locknutwasher 162 is configured as a ring or ring-like member, having proximaland distal circular open ends which are in the direction of, andtransversely face, the longitudinal axis of the reactor rotary mixingassembly (RRMA) 104, and which facilitate longitudinal passagetherethrough of the rotor shaft 152. For each rotatable paired set 158,the locknut 160 and the paired locknut washer 162 are configured forbeing immediately adjacent and opposite to each other when positionedand fixedly mounted on the rotor shaft 152. Such configuration isindicated, for example, in FIG. 23 by the two-headed dashed line arrow161, and shown, for example, in FIG. 1 (components 158 a and 158 b).

In exemplary embodiments, the reactor rotary mixing assembly (RRMA) 104additionally includes at least one rotatable paired set 158 of a locknut160 and a locknut washer 162, located at one or more of the followingpositions (i), (ii), (iii), or/and (iv) on the rotor shaft 152. (i)Between the distal face of the proximal rotatable lubricated cartridgeseal 148 and the proximal face of the proximal rotatable dynamic seal144. (ii) Between the proximal face of the distal rotatable lubricatedcartridge seal 150 and the distal face of the distal rotatable dynamicseal 146. (iii) Between the rotor tubular portion 170 distal open endand the proximal face of the distal rotatable dynamic seal 146. (iv)Between the rotor tubular portion 170 proximal open end and the distalface of the proximal rotatable dynamic seal 144. FIG. 5 shows explodedperspective views of the exemplary embodiments (i), (ii), and (iii),corresponding to one proximal rotatable paired set 158 a, and two distalrotatable paired sets 158 b and 158 c, respectively, of the locknut 160and the locknut washer 162.

Rotor-Based Performance and Process Control Structural Features

In exemplary embodiments of the chemical reactor 100, in general, and ofthe rotor 140, in particular, the rotor 140 is configured with at leastone rotor-based performance and process control structural featureselected from the group consisting of: openings, protrusions, anddepressions. In exemplary embodiments, the openings are in the form ofholes or slits that pass entirely through the thickness of one or moreportions of the rotor 140; the protrusions are in the form of teeth orspikes, or mounds that outwardly protrude (project, extend) from thesurface(s) of one or more portions of the rotor 140; and the depressionsare in the form of inverse mounds that inwardly protrude (project,extend) into (but, not entirely through) the surface(s) of one or moreportions of the rotor 140.

The one or more portions of the rotor 140 that is/are so configured withthe at least one rotor-based performance and process control structuralfeature (i.e., openings, protrusions, depressions), corresponds to atleast one rotor blade 180 of the rotor 140, namely, one rotor blade 180of the rotor 140, or several (but not all) rotor blades 180 of the rotor140, or all rotor blades 180 of the rotor 140. Accordingly, in exemplaryembodiments, the openings are in the form of holes or slits that passentirely through the radially curved thickness of one or more portionsof the rotor blades 180; the protrusions are in the form of teeth orspikes, or mounds that outwardly protrude (project, extend) from theradially curved surface(s) of one or more portions of the rotor blades180; and the depressions are in the form of inverse mounds that inwardlyprotrude (project, extend) into (but, not entirely through) the radiallycurved thickness of one or more portions of the rotor blades 180.

In exemplary embodiments wherein the rotor 140 includes the rotorcentral reinforcement disc 190, optionally, alternatively, oradditionally, the one or more portions of the rotor 140 that is/are soconfigured with the one or more rotor-based performance and processcontrol structural features (i.e., openings, protrusions, depressions),corresponds to at least a portion of the rotor central reinforcementdisc 190, namely, one (triangular like) sector 190 s of the rotorcentral reinforcement disc 190 of the rotor 140, or several (but notall) (triangular like) sectors 190 s of the rotor central reinforcementdisc 190 of the rotor 140, or all (triangular like) sectors 190 s of therotor central reinforcement disc 190 of the rotor 140. Accordingly, inexemplary embodiments, the openings are in the form of holes or slitsthat pass entirely through the thickness of one or more sectors 190 s ofthe rotor central reinforcement disc 190; the protrusions are in theform of teeth or spikes, or mounds that outwardly protrude (project,extend) from the thickness and surface(s) of one or more sectors 190 sof the rotor central reinforcement disc 190; and the depressions are inthe form of inverse mounds that inwardly protrude (project, extend) into(but, not entirely through) the thickness of one or more sectors 190 sof the rotor central reinforcement disc 190.

As illustratively described below, according to such exemplaryembodiments, the rotor based performance and process control structuralfeatures (i.e., openings, protrusions, depressions) are configured(shaped and sized) so as to facilitate ‘fine-tuning’ type additionalcontrolling performance of the rotor 140, in particular, and of thechemical reactor 100, in general, which, in turn, translates intoproviding an additional layer or level of control of the numerous(chemical reaction related) physicochemical processes taking placeinside the reactor central housing 110 (i.e., inside the chemicalreaction chamber 115) during operation of the chemical reactor 100. Insuch exemplary embodiments, compared to the rotor 140 configured withoutthe rotor-based performance and process control structural features, therotor 140 configured with the rotor-based performance and processcontrol structural features facilitates such ‘fine-tuning’ additionalcontrolling of the performance of the rotor 140, and of the chemicalreactor 100, thereby providing the additional layer or level of controlof the numerous (chemical reaction related) physicochemical processestaking place inside the reactor central housing 110 (chemical reactionchamber 115) during operation of the chemical reactor 100.

As illustratively described hereinabove, in exemplary embodiments,during operation of the chemical reactor 100 (and inside the chemicalreaction chamber 115), the intended direction of rotation of the rotor140 (when fixedly mounted on (connected, attached to) the rotor shaft152), and of the other selected components (i.e., of the reactor rotarymixing assembly (RRMA)) of the chemical reactor 100 that also rotate, is‘clockwise’, as indicated, for example, in FIGS. 2A, 2B, and 17A, 18A,by the reference letter R alongside the curved arrow pointing in theclockwise direction. According to such exemplary embodiments, the convexfaces (surfaces) of the rotor blades 180 are the leading or front faces(surfaces) during the clockwise rotation of the rotor 140, and theconcave faces (surfaces) of the rotor blades 180 are the trailing orback faces (surfaces) during the clockwise rotation of the rotor 140.During the clockwise rotation of the rotor 140, the convex leading orfront faces (surfaces) ‘forcibly’ impinge upon, physically(mechanically) engage and interact with, and drive the contents (i.e.,the solid/liquid/vapor/gas mixture) inside the reactor central housing110 (i.e., inside the chemical reaction chamber 115).

The same intended (clockwise) direction of rotation R of the rotor 140(when fixedly mounted on (connected, attached to) the rotor shaft 152)is applicable to the exemplary embodiments wherein at least one of therotor blades 180 is configured with at least one rotor-based performanceand process control structural feature (i.e., openings, or/andprotrusions, or/and depressions). In such exemplary embodiments, therotor-based performance and process control structural feature ofopenings (i.e., holes or/and slits) pass entirely through the one ormore rotor blades 180, and therefore, pass entirely through the leadingor front convex faces (surfaces) and the trailing or back faces(surfaces) of the rotor blades 180. Accordingly, in such exemplaryembodiments, the two other rotor-based performance and process controlstructural features of protrusions or/and depressions are configuredonly on the leading or front convex faces (surfaces) of the rotor blades180. Such exemplary embodiments are shown, for example, in FIGS. 24-36.

During the clockwise rotation of the rotor 140, the rotor-basedperformance and process control structural features (openings, or/andprotrusions, or/and depressions) that are configured on or/and throughone or more of the rotor blades 180, or/and optionally, configured onor/and through one or more portions of the rotor central reinforcementdisc 190, ‘forcibly’ impinge upon, physically (mechanically) engage andinteract with, and drive the contents (i.e., the solid/liquid/vapor/gasmixture) inside the reactor central housing 110 (i.e., inside thechemical reaction chamber 115) of the chemical reactor 100. Such‘forcible’ impingement upon, physical (mechanical) engagement andinteraction with, and driving of, the contents inside the chemicalreaction chamber 115 provide additional mechanisms for the numerous(chemical reaction related) physicochemical processes of mass and heattransfer, mixing, degradation, and catalytic chemical conversion, thattake place during operation of the chemical reactor 100. In turn, suchadditional mechanisms enhance, for example, by expediting (by reducingtime requirements) or/and improving energy efficiency (by reducingenergy requirements) of the overall catalytic chemical conversionprocess encompassing initial input conversion of the organic materialsand output production of diesel and other liquid fuels.

FIGS. 24 through 36 are different schematic views of exemplaryembodiments of the rotor 140 (i.e., rotor blades 180 or/and rotorcentral reinforcement disc 190) configured with several exemplaryrotor-based performance and process control structural features in theforms of (hole or slit) openings, or/and (teeth or spike, or mound)protrusions, or/and (inverse mound) depressions. In FIGS. 24-36,exemplary hole openings are indicated as ‘holes 140 ho’, exemplary slitopenings are indicated as ‘slits 140 s 1’, exemplary teeth or spikeprotrusions are indicated as ‘teeth, spikes 140 tsp’, exemplary moundprotrusions are indicated as ‘mounds 140 mo’, and exemplary inversemound depressions are indicated as ‘inverse mounds imo’. The holes 140ho or slits 140 s 1 pass entirely through the indicated portions (of arotor blade 180, or of a sector 190 s of the rotor central reinforcementdisc 190) of the rotor 140; the teeth or spikes 140 tsp, or mounds 140mo outwardly protrude (project, extend) from the surface(s) of theindicated portions (of a rotor blade 180, or of a sector 190 s of therotor central reinforcement disc 190) of the rotor 140; and the inversemounds 140 imo inwardly protrude (project, extend) into (but, notentirely through) the surface(s) of the indicated portions (of a rotorblade 180, or of a sector 190 s of the rotor central reinforcement disc190) of the rotor 140.

FIGS. 24A and 24B are schematic perspective views of an exemplaryembodiment of the rotor 140, with rotor-based performance and processcontrol structural features, being hole type openings 140 ho in oneblade 180, and in all blades 180, respectively. FIGS. 25A and 25B areschematic perspective views of an exemplary embodiment of the rotor 140,with rotor-based performance and process control structural features,being slit type openings 140 s 1 in one blade 180, and in all blades180, respectively.

FIGS. 26A and 26B are schematic perspective views of an exemplaryembodiment of the rotor 140, with rotor-based performance and processcontrol structural features, being teeth or spike type protrusions 140tsp on the convex face (surface) of one blade 180, and of all blades180, respectively. FIGS. 27A and 27B are schematic perspective views ofan exemplary embodiment of the rotor 140, with rotor-based performanceand process control structural features, being mound type protrusions140 mo on the convex face (surface) of one blade 180, and of all blades180, respectively.

FIGS. 28A and 28B are schematic perspective views of an exemplaryembodiment of the rotor 140, with rotor-based performance and processcontrol structural features, being inverse mound type depressions 140imo in the convex face (surface) of one blade 180, and of all blades180, respectively.

FIGS. 29A and 29B are schematic perspective views of an exemplaryembodiment of the rotor 140, with rotor-based performance and processcontrol structural features, being hole type openings 140 ho in onesector 190 s, and in all sectors 190 s, respectively, of the rotorcentral reinforcement disc 190. FIGS. 30A and 30B are schematicperspective views of an exemplary embodiment of the rotor 140, withrotor-based performance and process control structural features, beingslit type openings 140 sl in one sector 190 s, and in all sectors 190 s,respectively, of the rotor central reinforcement disc 190.

FIGS. 31A and 31B are schematic perspective views of an exemplaryembodiment of the rotor 140, with rotor-based performance and processcontrol structural features, being teeth or spike type protrusions 140tsp on the distal face (surface) of one sector 190 s, and of all sectors190 s, respectively, of the rotor central reinforcement disc 190. FIGS.32A and 32B are schematic perspective views of an exemplary embodimentof the rotor 140, with rotor-based performance and process controlstructural features, being teeth or spike type protrusions 140 tsp onthe proximal face (surface) of one sector 190 s, and of all sectors 190s, respectively, of the rotor central reinforcement disc 190. FIGS. 33Aand 33B are schematic perspective views of an exemplary embodiment ofthe rotor 140, with rotor-based performance and process controlstructural features, being mound type protrusions 140 mo on the distalface (surface) of one sector 190 s, and of all sectors 190 s,respectively, of the rotor central reinforcement disc 190. FIGS. 34A and34B are schematic perspective views of an exemplary embodiment of therotor 140, with rotor-based performance and process control structuralfeatures, being mound type protrusions 140 mo on the proximal face(surface) of one sector 190 s, and of all sectors 190 s, respectively,of the rotor central reinforcement disc 190.

FIGS. 35A and 35B are schematic perspective views of an exemplaryembodiment of the rotor 140, with rotor-based performance and processcontrol structural features, being inverse mound type depressions 140imo in the distal face (surface) of one sector 190 s, and of all sectors190 s, respectively, of the rotor central reinforcement disc 190. FIGS.36A and 36B are schematic perspective views of an exemplary embodimentof the rotor 140, with rotor-based performance and process controlstructural features, being inverse mound type depressions 140 imo in theproximal face (surface) of one sector 190 s, and of all sectors 190 s,respectively, of the rotor central reinforcement disc 190.

In addition to the exemplary embodiments shown in FIGS. 24-36 of therotor 140 (i.e., rotor blades 180 or/and rotor central reinforcementdisc 190) configured with the herein disclosed exemplary rotor-basedperformance and process control structural features, numerous otherexemplary embodiments are possible for implementing the invention. Forexample, additional exemplary embodiments wherein the rotor 140 isconfigured with rotor-based performance and process control structuralfeatures, being any combination of hole openings 140 ho, slit openings140 s 1, teeth or spike protrusions 140 tsp, mound protrusions 140 mo,and inverse mount depressions 140 imo, in one or more rotor blades 180,or/and in one or more sectors 190 s of the rotor central reinforcementdisc 190.

A first specific additional example is wherein the rotor 140 isconfigured with rotor-based performance and process control structuralfeatures, being a combination of hole openings 140 ho and slit openings140 s 1 in all blades 180 of the rotor 140. A second specific additionalexample is wherein the rotor 140 is configured with rotor-basedperformance and process control structural features, being a combinationof teeth or spike protrusions 140 tsp and mound protrusions 140 mo inall blades 180 of the rotor 140. A third specific additional example iswherein the rotor 140 is configured with rotor-based performance andprocess control structural features, being a combination of holeopenings 140 ho and slit openings 140 s 1 in all sectors 190 s of therotor central reinforcement disc 190.

There are different possible ways of making or forming the hereindisclosed rotor-based performance and process control structuralfeatures of openings, protrusions, and depressions in or/and on therotor 140 (without or with the optional rotor central reinforcement disc190). In a first exemplary way, after making the herein disclosed rotor140 (without or with the optional rotor central reinforcement disc 190),there is using drilling, cutting, welding, carving (engraving) toolsor/and devices for forming selected herein disclosed hole openings 140ho, slit openings 140 s 1, teeth or spike protrusions 140 tsp, moundprotrusions 140 mo, or/and inverse mount depressions 140 imo, in one ormore rotor blades 180, or/and in one or more sectors 190 s of the rotorcentral reinforcement disc 190, in the rotor 140. In a second exemplaryway, there is appropriately modifying a (conventional type, or 3Dprinting type) casting mold used in a respective (conventional or 3Dprinting) casting process that produces the herein disclosed rotor 140(without or with the optional rotor central reinforcement disc 190).Specifically, by incorporating into the design and making of the(conventional type, or 3D printing type) casting mold used for formingthe rotor 140, selected herein disclosed hole openings 140 ho, slitopenings 140 s 1, teeth or spike protrusions 140 tsp, mound protrusions140 mo, or/and inverse mount depressions 140 imo, in one or more rotorblades 180, or/and in one or more sectors 190 s of the rotor centralreinforcement disc 190. Then, there is using such modified casting moldto cast the rotor 140 having the selected openings, protrusions, or/anddepressions, via a conventional type or 3D printing type castingprocess.

Exemplary Applications of the Chemical Reactor

Hereinabove illustratively described exemplary embodiments of thechemical reactor 100 are particularly applied for performing catalyticthermal conversion of organic materials (e.g., coal, plastics, rubber,plant matter, wood shavings, biomass, organic wastes, among variousother possible organic materials) into diesel and other liquid fuels(e.g., automobile or/and jet engine fuels). For effecting suchapplication, the chemical reactor 100, in general, and the rotor shaft152, in particular, need to be operatively connected to appropriateequipment that powers and drives (rotates) the rotor shaft 152 and therotor 140, which, in turn, drives the numerous (chemical reactionrelated) physicochemical processes of mass and heat transfer, mixing,degradation, and catalytic chemical conversion, taking place inside thechemical reaction chamber 115 during operation of the chemical reactor100.

The chemical reactor 100, in general, and the rotor shaft 152, inparticular, are operably connectable to a rotor shaft drive unit (forexample, rotor shaft drive unit 300 shown in FIGS. 37 and 38) that isconfigured for driving (powering) and rotating the rotor shaft 152,which, in turn, translates to driving and rotating the rotor 140, andthe other components [i.e., of the reactor rotary mixing assembly(RRMA)] of the chemical reactor 100 that also rotate. As illustrativelydescribed hereinabove (with reference to FIGS. 21A, 21B), in exemplaryembodiments, such operable connection between the rotor shaft 152 andthe rotor shaft drive unit 300 is facilitated by the rotor shaft 152additionally including a rotor shaft drive unit connecting and fixingportion 250 located along the distal end portion 152 dep of the rotorshaft 152.

FIG. 37 is a schematic diagram of an exemplary application of thechemical reactor 100, highlighting the chemical reactor 100 operativelyconnected to an exemplary rotor shaft drive unit 300. In FIG. 37,operative connection (at the distal side) of the chemical reactor 100 tothe exemplary rotor shaft drive unit 300 is generally indicated as, andreferenced by, the dashed lines having reference number 302 andextending between the rotor shaft distal end portion 152 dep (thatincludes the rotor shaft drive unit connecting and fixing portion 250)and the rotor shaft drive unit 300. In such exemplary application, forexample, the rotor shaft drive unit connecting and fixing portion 250 isoperably connected (indicated by the dotted line 310 a) to ashaft-to-shaft coupling device 310, which, in turn is operably connected(indicated by the dotted line 310 b) to the motor of the rotor shaftdrive unit 300. In exemplary embodiments, the rotor shaft drive unit 300includes a power supply 304, a motor 306, and a power interface andcontrol assembly 308.

The motor 306 mechanically engages with, and drives, the rotor shaft152, which then turns and rotates the rotor 140, and all other(rotatable) components of the reactor rotary mixing assembly (RRMA) 104that are fixedly mounted on the rotor shaft 152 and which also rotateinside the chemical reactor 100. Such mechanical engagement and drivingis facilitated, for example, by the motor 306 having a motorized driveshaft operably connected (indicated by dotted line 310 b) to theshaft-to-shaft coupling device 310, which, in turn, is operablyconnected (indicated by dotted line 310 a) to the distal end portion 152dep (that includes the rotor shaft drive unit connecting and fixingportion 250) of the rotor shaft 152.

The power interface and control assembly 308 interfaces between thepower supply 304 and the motor 306, and controls operation (andoperational parameters [e.g., power level, rate of rotation of themotorized drive shaft]) of the motor 306, which, then translates tocontrolling operation (and operational parameters [e.g., rotor speed, orrate of rotation]) of the rotor 140, during operation of the chemicalreactor 100. In exemplary embodiments, the power interface and controlassembly 308 includes a variable frequency drive that facilitates suchoperational control of the motor 306, by controlling power frequency ofthe motor 306, and of its motorized drive shaft.

In exemplary embodiments, the rotor shaft drive unit 300 additionallyincludes, or is operatively connected to, a process control anddata-information processing unit (e.g., a computerized platform withassociated hardware and software), configured for controlling operationof and processing data-information associated with the rotor shaft driveunit 300, during operation of the rotor shaft drive unit 300, and of thechemical reactor 100. In exemplary embodiments, the process control anddata-information processing unit includes, or is operatively connectedto, a display device that enables an operator to view, and use, the dataand information relating to, and generated during, operation of therotor shaft drive unit 300, and of the chemical reactor 100.

In exemplary embodiments, the chemical reactor 100 is included in, andis operably connectable (e.g., at its proximal side) to, an overall,more encompassing, catalytic thermal conversion system, for example, asillustratively described below with reference to FIG. 38.

FIG. 38 is a schematic diagram of another exemplary application of thechemical reactor 100, highlighting an exemplary catalytic thermalconversion system 400 that includes the chemical reactor 100. As shownin FIG. 38, exemplary catalytic thermal conversion system 400 includes:the chemical reactor 100; a rotor shaft drive unit, for example, therotor shaft drive unit 300 (as illustratively described above and shownin FIG. 37); and catalytic conversion system process units, for example,catalytic conversion system process units 410. In exemplary embodiments,the catalytic conversion system 400 additionally includes a processcontrol and data-information processing unit, for example, processcontrol and data-information processing unit 430.

The chemical reactor 100 is any of the above illustratively describedexemplary embodiments of the herein disclosed chemical reactor with highspeed rotary mixing, for catalytic conversion of organic materials intodiesel and other liquid fuels.

The rotor shaft drive unit 300 is that illustratively described abovewith reference to FIG. 37. Accordingly, the chemical reactor 100, at itsdistal side, is operatively connected (indicated by dashed lines 302) tothe rotor shaft drive unit 300. Such operative connection is madebetween the rotor shaft distal end portion 152 dep (that includes therotor shaft drive unit connecting and fixing portion 250) and the rotorshaft drive unit 300. The rotor shaft drive unit 300 is configured fordriving (powering) and rotating the rotor shaft 152 (which, in turn,drives and rotates all other components of the reactor rotary mixingassembly (RRMA) 104) of the chemical reactor 100.

The chemical reactor 100 is operatively connected to the exemplarycatalytic thermal conversion system process units 410, for example, asgenerally indicated, and referenced, by the two dashed line,double-headed arrows having reference number 420 and extending betweenthe chemical reactor 100 and the catalytic thermal conversion systemprocess units 410. In exemplary embodiments, the exemplary catalyticthermal conversion system process units 400, in a non-limiting manner,are those among the numerous well established and widely practicedstandard chemical engineering operations types of process units. Forexample, (liquid, solid, gas, vapor) materials input/output transfer andhandling types of process units, such as distillation, evaporation,condensation, and decanting, among other kinds of possible materialsseparations types of process units that may be applicable to performingan overall catalytic thermal conversion process.

As shown in FIG. 38, in exemplary embodiments, the catalytic thermalconversion system 400 additionally includes the process control anddata-information processing unit 430, operatively connected to, and,configured for controlling operation of and processing data-informationassociated with, the other units (and components therein) of thecatalytic thermal conversion system 400, namely, the chemical reactor100, the rotor shaft drive unit 300, and the catalytic thermalconversion system process units 410. Operative connections andconfigurations between the process control and data-informationprocessing unit 430 and each of the other catalytic thermal conversionsystem units (and components therein) are schematically represented bythe double headed dotted line arrows 435 extending between the processcontrol and data-information processing unit 430 and each of the othercatalytic thermal conversion system units (i.e., the chemical reactor100, the rotor shaft drive unit 300, and the catalytic thermalconversion system process units 410).

In exemplary embodiments, such operative connections and configurationsbetween the process control and data-information processing unit 430,and each of the other system units (and components therein), namely, thechemical reactor 100, the rotor shaft drive unit 300, and the catalyticthermal conversion system process units 410, include (wired or/andwireless) electrical or/and electronic network of input/outputdata-information control signal communications lines, for example, inFIG. 38, also represented by double headed dotted line arrows 420. Inexemplary embodiments, electrical or/and electronic input/output,feedforward and feedback transmission and reception of electrical or/andelectronic control data, information, and command, communication signalsbetween system units, components, and assemblies, mechanisms, and, powersupply and process control equipment, are provided by (wired or/andwireless) electrical or/and electronic input/output control data,information, and command, communications lines, which may include, forexample, cables, bundles, or/and buses of wires. In exemplaryembodiments, the catalytic thermal conversion system 400, in general,and, the process control and data-information processing unit 430, inparticular, includes automatic electrical or/and electronic operating,controlling, and monitoring (measuring) of the numerous operatingparameters and conditions of system units, components, assemblies,mechanisms, and operative connections.

In accordance with the preceding illustratively described exemplaryapplications of the herein disclosed chemical reactor, another aspect ofthe invention is of a system for catalytically thermally convertingorganic materials into diesel and other liquid fuels. The system (forexample, the system 400 shown in FIG. 38) for catalytically thermallyconverting organic materials into diesel and other liquid fuels, in anon-limiting manner, and in some embodiments, includes: a chemicalreactor 100 that includes a reactor stationary assembly (RSA) 102,configured with only stationary components that remain stationary duringoperation of the chemical reactor 100, and a reactor rotary mixingassembly (RRMA) 104, configured with only rotatable components thatrotate during operation of the chemical reactor 100. The system 400further includes a rotor shaft drive unit (for example rotor shaft driveunit 300), operatively connected to the reactor rotary mixing assembly(RRMA) 104, and configured for driving and rotating the reactor rotarymixing assembly (RRMA) 104 relative to the reactor stationary assembly(RSA) 102. The system 400 further includes catalytic conversion systemprocess units (for example, the catalytic conversion system processunits 410), operatively connected to the chemical reactor 100. Inexemplary embodiments, the catalytic thermal conversion system 400additionally includes the process control and data-informationprocessing unit 430, operatively connected to, and, configured forcontrolling operation of and processing data-information associatedwith, the other units (and components therein) of the catalytic thermalconversion system 400, namely, the chemical reactor 100, the rotor shaftdrive unit 300, and the catalytic thermal conversion system processunits 410.

Additionally, in accordance with the preceding illustratively describedexemplary applications of the herein disclosed chemical reactor, anotheraspect of the invention is of a method for catalytically thermallyconverting organic materials into diesel and other liquid fuels. Themethod for catalytically thermally converting organic materials intodiesel and other liquid fuels, in a non-limiting manner, and in someembodiments, includes: providing a chemical reactor (for example, thechemical reactor 100) that includes a reactor stationary assembly (RSA)102, configured with only stationary components that remain stationaryduring operation of the chemical reactor 100, and a reactor rotarymixing assembly (RRMA) 104, configured with only rotatable componentsthat rotate during operation of the chemical reactor 100. The methodfurther includes operatively connecting the reactor rotary mixingassembly (RRMA) 104 to a rotor shaft drive unit (for example, the rotorshaft drive unit 300), so as to drive and rotate the reactor rotarymixing assembly (RRMA) 104 relative to the reactor stationary assembly(RSA) 102. The method further includes operatively connecting thechemical reactor to catalytic conversion system process units (forexample, catalytic conversion system process units 410), and operatingthe chemical reactor 100 and the catalytic conversion system processunits 410, so as to thermally convert organic materials into diesel andother liquid fuels. In exemplary embodiments, the method furtherincludes controlling operation of and processing data-informationassociated with, the chemical reactor 100, the rotor shaft drive unit300, and the catalytic thermal conversion system process units 410.

Exemplary Materials of Construction and Ranges of Size Dimensions ofComponents, Elements, and Structural Features, of the Herein DisclosedChemical Reactor

The following, in a non-limiting manner, is presentation of exemplarymaterials of construction and ranges of size dimensions of components,elements, and structural features, of the herein disclosed chemicalreactor. Implementation and practice of embodiments of the hereindisclosed invention are not limited to the below presented exemplarymaterials and ranges of size dimensions. Alternative or additionalmaterials of construction and size dimensions may be used forimplementing and practicing embodiments of the herein disclosedinvention.

Hereinbelow, regarding exemplary materials of construction, theinternationally known and used terms ASTM, UNS, DIN, and SAE areabbreviations for: American Society for Testing and Materials, UnifiedNumbering System, German Institute for Standardization, and Society ofAutomotive Engineers, respectively. Regarding exemplary ranges of sizedimensions, the dimensional unit of millimeter(s) [mm] is usedthroughout.

Reactor Stationary Assembly (RSA) 102 Reactor Central Housing 110

Cast iron (e.g., per ASTM: A536-84; UNS: F33800; DIN: EN-JS1060/EN-GJS-600-3).

Middle portion: (proximal to distal) longitudinal length (width): 180mm-800 mm; outer diameter: 200 mm-1200 mm; inner diameter: 250 mm-1030mm; wall thickness: 20-80 mm. Proximal and distal (flanged) open endswall thickness: 12 mm-50 mm. Anti-abrasion shield fixing pointcharacteristic size dimension (diameter, length, or width): 10 mm-100mm. Supporting and fixing elements characteristic size dimension (lengthor width): 150 mm-400 mm.

Reactor Input/Output Manifolds 112, 114

Abrasion resistant cast iron (e.g., per ASTM: A532, class III-24Cr).Circular base: diameter: 250 mm-1100 mm; thickness: 10 mm-40 mm. Input(suction) port: diameter: 75 mm-300 mm; length: 200 mm-800 mm. Inputaperture: width: 5 mm-60 mm; length: 75 mm-300 mm. Output (discharge)port: diameter: 60 mm-250 mm; length: 200 mm-800 mm. Output aperture:width: 5 mm-20 mm; length: 30 mm-150 mm. Drain port: diameter: 35 mm-150mm; length: 150 mm-800 mm. Drain aperture diameter: 35 mm-150 mm. Rotorshaft passageway (circular opening) diameter: 40 mm-200 mm.

Reactor Input/Output Manifold Housings 116, 118

Cast iron (e.g., per ASTM: A536-84; UNS: F33800; DIN: EN-JS1060/EN-GJS-600-3).

Circular base: diameter: 300 mm-1300 mm; thickness: 100 mm-400 mm. Input(suction) port channel diameter: 70 mm-280 mm. Output (discharge) portchannel diameter: 60 mm-240 mm. Drain port channel diameter: 40 mm-160mm. Rotor shaft passageway (circular opening) diameter: 40 mm-200 mm.

Dynamic Seal Housings 120, 122

Cast iron (e.g., per ASTM: A536-84; UNS: F33800; DIN: EN-JS1060/EN-GJS-600-3).

Circular base: diameter: 300 mm-1300 mm; thickness: 7 mm-30 mm. Tubularmember: diameter: 100 mm-400 mm; length: 30 mm-130 mm; wall thickness:10 mm-40 mm. Rotor shaft passageway (circular opening) diameter: 40mm-200 mm.

Lubricated Cartridge Seal Housings 124, 126

Cast iron (e.g., per ASTM: A536-84; UNS: F33800; DIN: EN-JS1060/EN-GJS-600-3).

Circular base: diameter: 300 mm-1300 mm; thickness: 10 mm-50 mm. Sealsupporting and holding member: diameter: 150 mm-700 mm; length: 100mm-450 mm; wall thickness: 50 mm-200 mm. Support arm height: 100 mm-450mm. Rotor shaft passageway (circular opening) diameter: 40 mm-200 mm.

Anti-Abrasion Shield 128

Abrasion resistant cast iron (e.g., per ASTM: A532, class III-24Cr).

Body: (proximal to distal) longitudinal length (width): 170 mm-750 mm;outer diameter: 180 mm-1100 mm; inner diameter: 200 mm-900 mm; wallthickness: 20-80 mm. Fixing elements characteristic size dimension(length or width): 150 mm-400 mm.

Reactor Rotary Mixing Assembly (RRMA) 104 Rotor 140

Abrasion resistant cast iron (e.g., per ASTM: A532, class III-24Cr).

> rotor tubular portion inner diameter: 40 mm-200 mm.

> rotor blades: number of rotor blades: 4-30; rotor blade longitudinallength LL: 180 mm-700 mm; rotor blade curved radial length CL: 75 mm-300mm; rotor blade thickness TK: 7 mm-30 mm; rotor blade angle of curvaturea: 3 degrees-80 degrees.

> rotor central reinforcement disc: (radially directed) disc diameter:200 mm-800 mm; (longitudinally directed) disc thickness: 10 mm-40 mm.

Rotatable Dynamic Seals 144, 146

Cast iron (e.g., per ASTM: A536-84; UNS: F33800; DIN: EN-JS1060/EN-GJS-600-3).

Circular base: diameter: 200 mm-900 mm; thickness: 12 mm-50 mm. Starfish like member: number of curved arms: 2-24; each arm: curved width: 7mm-30 mm; curved length: 150 mm-600 mm; height: 2 mm-8 mm. Rotor shaftpassageway (circular opening) diameter: 40 mm-200 mm.

Rotatable Lubricated Cartridge Seals 148, 150

Type: single cartridge.

Stainless steel (e.g., per SAE grade 316; UNS: S31600).

Lubricant flow receiver and transfer member: diameter: 50 mm-250 mm;length: 15 mm-80 mm. Support member: diameter: 45 mm-220 mm. Rotor shaftpassageway (circular opening) diameter: 40 mm-200 mm.

Rotatable Rotor Shaft 152

Chromium molybdenum steel (e.g., per ASTM: 4140; UNS: 1.7225/42crmo4;DIN: G41400).

Shaft: longitudinal length: 800 mm-3,000 mm; tapered diameters: 35mm-195 mm.

Reactor rotary mixing assembly (RRMA) component mounting and fixingportion or section: area: 350 mm2-3500 mm2 (for an ellipse, circle,rectangle, or square).

Rotor shaft drive unit connecting and fixing portion: area: 350 mm2-3500mm2 (for an ellipse, circle, rectangle, or square).

Proximal extension of the proximal-most longitudinal end of the rotorshaft beyond the fixed position of the proximal rotatable cartridgebearing: 2 mm-20 mm.

Distal extension of the distal-most longitudinal end of the rotor shaftbeyond the fixed position of the distal rotatable cartridge bearing: 50mm-200 mm.

Rotatable Cartridge Bearings 154, 156

Type: piloted flange bearing.

Stainless steel (e.g., per SAE grade 440A, B, or C; UNS: S44002, 3, or4).

Cartridge: diameter: 50 mm-250 mm; length: 10 mm-50 mm. Support member:

-   -   diameter: 45 mm-220 mm. Rotor shaft passageway (circular        opening) diameter: 40 mm-200 mm.

Rotatable Paired Sets 158 of a Locknut 160 and a Locknut Washer 162

Stainless Steel (e.g., Per SAE Grade 316; UNS: S31600).

Locknut, locknut washer: diameter: 50 mm-250 mm; length (width): 5 mm-20MM.

Latitudinal or Radial (Transverse) Offset λ of Reactor Components

10 mm-60 mm.

Rotor-Based Performance and Process Control Structural Features

> hole openings 140 ho (FIGS. 24A, 24B, 29A, 29B): diameter: 3 mm-10 mm.

> slit openings 140 s 1 (FIGS. 25A, 25B, 30A, 30B): length: 3 mm-10 mm;width: 3 mm-10 mm.

> teeth or spike protrusions 140 tsp (FIGS. 26A, 26B, 31A, 31B, 32A,32B): base diameter: 3 mm-10 mm; height: 3 mm-10 mm.

> mound protrusions 140 mo (FIGS. 27A, 27B, 33A, 33B, 34A, 34B): length:3 mm-10 mm; width: 3 mm-10 mm; height: 3 mm-10 mm.

> inverse mound depressions 140 imo (FIGS. 28A, 28B, 35A, 35B, 36A,36B):

-   -   length: 3 mm-10 mm; width: 3 mm-10 mm; depth: 3 mm-10 mm.

Exemplary Operating Conditions and Parameters in Applications of theChemical Reactor

The following, in a non-limiting manner, is presentation of exemplaryoperating conditions and parameters in applications of the hereindisclosed chemical reactor. Implementation and practice of embodimentsof the herein disclosed invention are not limited to the below presentedexemplary operating conditions and parameters. Alternative or additionaloperating conditions and parameters may be used for implementing andpracticing embodiments of the herein disclosed invention.

Rotor Shaft Drive Unit 300

> Power supply: 440/220 volts, 50/60 Hz (Hertz); city power grid(regular AC power for industrial use); or electrical AC power generator(powered by diesel or gas fuel); or renewable energy source (solaror/and wind AC power).

> Motor: power generation: 100-1,000 Kw (kilowatts)/134-1,340 hp(horsepower); drive shaft rate of rotation 400-5,000 rpm (rounds perminute).

> Variable frequency drive: 10 Hz-50/60 Hz.

Chemical Reactor 100

> Input (feed) materials to be catalytically converted: organic(hydrocarbon-containing) materials, singly, or in combination; coal,plastics, rubber, plant matter, wood shavings, biomass, organic wastes.

> Material mass flow rate (entering, exiting the chemical reactor) [at160° C.]:

200-500 GPM (gallons per minute)/750-1890 L/min (liters per minute).

> Reaction temperature (inside the chemical reaction chamber): 150°C.-380° C.

> Reaction pressure (inside the chemical reaction chamber): 0.5-5bar/0.49-4.9 atm/375-3,750 mm Hg/50-500 kPa (kilopascal).

> Rotational Speed (of rotor shaft 152, with other components of theRRMA 104):

400-5,000 rpm.

> Main output (product) materials: aliphatic hydrocarbons (C5-C44);diesel fuel (C10-C22), kerosene, gasoline, jet fuel.

Each of the following terms written in singular grammatical form: ‘a’,‘an’, and ‘the’, as used herein, means ‘at least one’, or ‘one or more’.Use of the phrase ‘one or more’ herein does not alter this intendedmeaning of ‘a’, ‘an’, or ‘the’. Accordingly, the terms ‘a’, ‘an’, and‘the’, as used herein, may also refer to, and encompass, a plurality ofthe stated entity or object, unless otherwise specifically defined orstated herein, or, unless the context clearly dictates otherwise. Forexample, the phrases: ‘a unit’, ‘a device’, ‘an assembly’, ‘amechanism’, ‘a component’, ‘an element’, and ‘a step or procedure’, asused herein, may also refer to, and encompass, a plurality of units, aplurality of devices, a plurality of assemblies, a plurality ofmechanisms, a plurality of components, a plurality of elements, and, aplurality of steps or procedures, respectively.

Each of the following terms: ‘includes’, ‘including’, ‘has’, ‘having’,‘comprises’, and ‘comprising’, and, their linguistic/grammaticalvariants, derivatives, or/and conjugates, as used herein, means‘including, but not limited to’, and is to be taken as specifying thestated component(s), feature(s), characteristic(s), parameter(s),integer(s), or step(s), and does not preclude addition of one or moreadditional component(s), feature(s), characteristic(s), parameter(s),integer(s), step(s), or groups thereof. Each of these terms isconsidered equivalent in meaning to the phrase ‘consisting essentiallyof’.

Each of the phrases ‘consisting of’ and ‘consists of’, as used herein,means ‘including and limited to’.

The phrase ‘consisting essentially of’, as used herein, means that thestated entity or item (system, system unit, system sub-unit, device,assembly, sub-assembly, mechanism, structure, component, element, or,peripheral equipment, utility, accessory, or material, method orprocess, step or procedure, sub-step or sub-procedure), which is anentirety or part of an exemplary embodiment of the disclosed invention,or/and which is used for implementing an exemplary embodiment of thedisclosed invention, may include at least one additional ‘feature orcharacteristic’ being a system unit, system sub-unit, device, assembly,sub-assembly, mechanism, structure, component, or element, or,peripheral equipment, utility, accessory, or material, step orprocedure, sub-step or sub-procedure), but only if each such additional‘feature or characteristic’ does not materially alter the basic noveland inventive characteristics or special technical features, of theclaimed entity or item.

The term ‘method’, as used herein, refers to a single step, procedure,manner, means, or/and technique, or a sequence, set, or group of two ormore steps, procedures, manners, means, or/and techniques, foraccomplishing or achieving a given task or action. Any such hereindisclosed method, in a non-limiting manner, may include one or moresteps, procedures, manners, means, or/and techniques, that are known orreadily developed from one or more steps, procedures, manners, means,or/and techniques, previously taught about by practitioners in therelevant field(s) and art(s) of the herein disclosed invention. In anysuch herein disclosed method, in a non-limiting manner, the stated orpresented sequential order of one or more steps, procedures, manners,means, or/and techniques, is not limited to that specifically stated orpresented sequential order, for accomplishing or achieving a given taskor action, unless otherwise specifically defined or stated herein, or,unless the context clearly dictates otherwise. Accordingly, in any suchherein disclosed method, in a non-limiting manner, there may exist oneor more alternative sequential orders of the same steps, procedures,manners, means, or/and techniques, for accomplishing or achieving a samegiven task or action, while maintaining same or similar meaning andscope of the herein disclosed invention.

Throughout this disclosure, a numerical value of a parameter, feature,characteristic, object, or dimension, may be stated or described interms of a numerical range format. Such a numerical range format, asused herein, illustrates implementation of some exemplary embodiments ofthe invention, and does not inflexibly limit the scope of the exemplaryembodiments of the invention. Accordingly, a stated or describednumerical range also refers to, and encompasses, all possible sub-rangesand individual numerical values (where a numerical value may beexpressed as a whole, integral, or fractional number) within that statedor described numerical range. For example, a stated or describednumerical range ‘from 1 to 6’ also refers to, and encompasses, allpossible sub-ranges, such as ‘from 1 to 3’, ‘from 1 to 4’, ‘from 1 to5’, ‘from 2 to 4’, ‘from 2 to 6’, ‘from 3 to 6’, etc., and individualnumerical values, such as ‘1’, ‘1.3’, ‘2’, ‘2.8’, ‘3’, ‘3.5’, ‘4’,‘4.6’, ‘5’, ‘5.2’, and ‘6’, within the stated or described numericalrange of ‘from 1 to 6’. This applies regardless of the numericalbreadth, extent, or size, of the stated or described numerical range.

Moreover, for stating or describing a numerical range, the phrase ‘in arange of between about a first numerical value and about a secondnumerical value’, is considered equivalent to, and meaning the same as,the phrase ‘in a range of from about a first numerical value to about asecond numerical value’, and, thus, the two equivalently meaning phrasesmay be used interchangeably. For example, for stating or describing thenumerical range of room temperature, the phrase ‘room temperature refersto a temperature in a range of between about 20° C. and about 25° C.’,is considered equivalent to, and meaning the same as, the phrase ‘roomtemperature refers to a temperature in a range of from about 20° C. toabout 25° C.’.

The term ‘about’, as used herein, refers to ±10% of the stated numericalvalue.

The phrase ‘operatively connected’, as used herein, equivalently refersto the corresponding synonymous phrases ‘operatively joined’, and‘operatively attached’. These phrases, as used herein, mean that thedescribed or/and shown entities are configured ‘connected’ to eachother, in an ‘operative’ (ready-for-operation/ready-for-use) manner.Such operative connection, operative joint, or operative attachment,between or among the entities is according to one type, or a pluralityof types, of a mechanical (physical, structural), or/and an electrical,or/and an electronic, or/and an electro-mechanical, connection orconnections, involving one or more corresponding type(s) or kind(s) ofmechanical (physical, structural), or/and electrical, or/and electronic,or/and electro-mechanical, equipment and components. Optionally, suchoperative connection, operative joint, or operative attachment, betweenor among the entities, may include, or may involve, one or more type(s)or kind(s) of computerized hardware or/and software equipment andcomponents.

The phrase ‘operably connectable’, as used herein, equivalently refersto the corresponding synonymous phrases ‘operably joinable to’, and‘operably attachable to’. These phrases, as used herein, mean that thedescribed or/and shown entities are configured ‘connectable’ to eachother (i.e., capable of being connected to each other, having ability tobe connected to each other, or having potential to be connected to eachother), for subsequently forming an ‘operative connection’, an‘operative joint’, or an ‘operative attachment’, between or among theentities. Such operable connectability, operable joinability, oroperable attachability, between or among the entities is according toone type, or a plurality of types, of a mechanical (physical,structural), or/and an electrical, or/and an electronic, or/and anelectro-mechanical, connection or connections, involving one or morecorresponding type(s) or kind(s) of mechanical (physical, structural),or/and electrical, or/and electronic, or/and electro-mechanical,equipment and components. Optionally, such operable connectability,operable joinability, or operable attachability, between or among theentities, may include, or may involve, one or more type(s) or kind(s) ofcomputerized hardware or/and software equipment and components.

It is to be fully understood that certain aspects, characteristics, andfeatures, of the invention, which are, for clarity, illustrativelydescribed and presented in the context or format of a plurality ofseparate embodiments, may also be illustratively described and presentedin any suitable combination or sub-combination in the context or formatof a single embodiment. Conversely, various aspects, characteristics,and features, of the invention which are illustratively described andpresented in combination or sub-combination in the context or format ofa single embodiment, may also be illustratively described and presentedin the context or format of a plurality of separate embodiments.

Although the invention has been illustratively described and presentedby way of specific exemplary embodiments, and examples thereof, it isevident that many alternatives, modifications, or/and variations,thereof, will be apparent to those skilled in the art. Accordingly, itis intended that all such alternatives, modifications, or/andvariations, are encompassed by the broad scope of the appended claims.

All publications, patents, and or/and patent applications, cited orreferred to in this disclosure are herein incorporated in their entiretyby reference into the specification, to the same extent as if eachindividual publication, patent, or/and patent application, wasspecifically and individually indicated to be incorporated herein byreference. In addition, citation or identification of any reference inthis specification shall not be construed or understood as an admissionthat such reference represents or corresponds to prior art of thepresent invention. To the extent that section headings are used, theyshould not be construed as necessarily limiting.

1. A chemical reactor with high speed rotary mixing, for catalyticthermal conversion of organic materials into diesel and other liquidfuels, the chemical reactor comprising: a reactor stationary assembly(RSA), configured with only stationary components that remain stationaryduring operation of the chemical reactor, and comprising: a reactorcentral housing, longitudinally extending proximally and distally, andhaving proximal and distal open ends; proximal and distal reactorinput/output manifolds, each of said manifolds is configured with alongitudinally directed rotor shaft passageway, and has a respectivedistal or proximal face that covers, and is sealed to, said reactorcentral housing proximal or distal open end, and each of said manifoldsis housed in a respective proximal or distal manifold housing havingproximal and distal faces and configured with a longitudinally directedrotor shaft passageway; proximal and distal dynamic seal housings, eachof said dynamic seal housings is configured with a longitudinallydirected rotor shaft passageway, and has a respective distal or proximalface that is sealed to said proximal or distal face of said proximal ordistal manifold housing, respectively; and proximal and distallubricated cartridge seal housings, each of said cartridge seal housingsis configured with a longitudinally directed rotor shaft passageway, andhas a respective distal or proximal face that is sealed to said proximalor distal face of said proximal or distal dynamic seal housing,respectively; and a reactor rotary mixing assembly (RRMA), configuredwith only rotatable components that rotate during operation of thechemical reactor, and comprising: a rotor, housed inside of said reactorcentral housing, and configured with a rotor tubular portionlongitudinally extending proximally and distally with proximal anddistal open ends, said rotor includes a plurality of radially curvedrotor blades that extend radially from, and longitudinally along, theouter circumferential periphery of said rotor tubular portion; proximaland distal rotatable dynamic seals, each of said dynamic seals isconfigured with a longitudinally directed rotor shaft passageway, and ishoused inside of said proximal or distal dynamic seal housing,respectively; proximal and distal rotatable lubricated cartridge seals,each of said cartridge seals is configured with a longitudinallydirected rotor shaft passageway, and is housed inside of said proximalor distal lubricated cartridge seal housing, respectively; and arotatable rotor shaft, longitudinally passing through said proximal anddistal open ends of said rotor and of said reactor central housing, andthrough said rotor shaft passageways of said proximal and distal reactorinput/output manifolds and said housings thereof, of said proximal anddistal dynamic seals and said housings thereof, and of said proximal anddistal lubricated cartridge seals and said housings thereof, said rotorshaft is fixedly connected to said rotor tubular portion so as tofacilitate controllable rotation of said rotor during operation of thechemical reactor.
 2. The chemical reactor of claim 1, wherein saidreactor stationary assembly additionally includes an anti-abrasionshield that shields the tubular inner surface of said reactor centralhousing from abrasion during operation of the chemical reactor, saidabrasion shield longitudinally extends proximally and distally inside ofsaid reactor central housing, having a proximal open end covered by, andsealed to, said distal face of said proximal reactor input/outputmanifold, and having a distal open end covered by, and sealed to, saidproximal face of said distal reactor input/output manifold.
 3. Thechemical reactor of claim 1, wherein at least one of said rotor bladesis configured with at least one rotor-based performance and processcontrol structural feature selected from the group consisting of:openings, protrusions, and depressions, whereby said rotor-basedperformance and process control structural features facilitatecontrolling performance of said rotor, so as to provide an additionallayer or level of control of chemical reaction related physicochemicalprocesses of mass and heat transfer, mixing, degradation, and catalyticchemical conversion, taking place inside of said reactor central housingduring operation of the chemical reactor.
 4. The chemical reactor ofclaim 3, wherein said openings are in a form of holes or slits passingentirely through the radially curved thickness of said at least one ofsaid rotor blades.
 5. The chemical reactor of claim 3, wherein saidprotrusions are in a form of teeth or spikes, or mounds protruding orprojecting out from the radially curved thickness of said at least oneof said rotor blades.
 6. The chemical reactor of claim 3, wherein saiddepressions are in a form of inverse mounds protruding or projectingpartly into, not entirely through, the radially curved thickness of saidat least one of said rotor blades.
 7. The chemical reactor of claim 1,wherein said rotor includes a rotor central reinforcement disc, havingproximal and distal circular faces, and a central opening concentricwith the circumferential periphery of said rotor tubular portion,thereby facilitating longitudinal passage therethrough of said rotorshaft.
 8. The chemical reactor of claim 7, wherein said rotor centralreinforcement disc is configured with at least one rotor-basedperformance and process control structural feature selected from thegroup consisting of: openings, protrusions, and depressions, wherebysaid rotor-based performance and process control structural featuresfacilitate controlling performance of said rotor, so as to provideadditional control of chemical reaction related physicochemicalprocesses of mass and heat transfer, mixing, degradation, and catalyticchemical conversion, taking place inside of said reactor central housingduring operation of the chemical reactor.
 9. The chemical reactor ofclaim 8, wherein said openings are in a form of holes or slits passingentirely through the thickness of said rotor central reinforcement disc.10. The chemical reactor of claim 8, wherein said protrusions are in aform of teeth or spikes, or mounds protruding or projecting out from thethickness of said rotor central reinforcement disc.
 11. The chemicalreactor of claim 8, wherein said depressions are in a form of inversemounds protruding or projecting partly into, not entirely through, thethickness of said rotor central reinforcement disc.
 12. The chemicalreactor of claim 1, wherein said rotor shaft is operably connectable toa rotor shaft drive unit that drives and rotates said rotor shaft.
 13. Areactor rotary mixing assembly, for use in a chemical reactor with highspeed rotary mixing, for catalytic thermal conversion of organicmaterials into diesel and other liquid fuels, the reactor rotary mixingassembly comprising: a rotor, configured with a rotor tubular portionlongitudinally extending proximally and distally with proximal anddistal open ends, said rotor includes a plurality of radially curvedrotor blades, that extend radially from, and longitudinally along, theouter circumferential periphery of said rotor tubular portion; proximaland distal rotatable dynamic seals, configured with respectivelongitudinally directed rotor shaft passageways, and located opposite toeach other with said rotor tubular member longitudinally positionedtherebetween; proximal and distal rotatable lubricated cartridge seals,configured with respective longitudinally directed rotor shaftpassageways, and located opposite to each other with said proximal anddistal dynamic seals longitudinally positioned therebetween; and arotatable rotor shaft, longitudinally passing through said rotorproximal and distal open ends, and through said rotor shaft passagewaysof said proximal and distal dynamic seals, and of said proximal anddistal lubricated cartridge seals, said rotor shaft is fixedly connectedto said rotor tubular portion so as to facilitate controllable rotationof said rotor during operation of the chemical reactor; wherein saidrotor includes a rotor central reinforcement disc, having proximal anddistal circular faces, and a central opening concentric with thecircumferential periphery of said rotor tubular portion, therebyfacilitating longitudinal passage therethrough of said rotor shaft, saidrotor central reinforcement disc transversely bisects the longitudinallengths of said rotor blades, and the outer circumferential periphery ofsaid rotor central reinforcement disc is transverse to, and coincideswith, the radial outer ends of said rotor blades.
 14. The reactor rotarymixing assembly of claim 13, wherein at least one of said rotor bladesis configured with at least one rotor-based performance and processcontrol structural feature selected from the group consisting of:openings, protrusions, and depressions, whereby said rotor-basedperformance and process control structural features facilitatecontrolling performance of said rotor, so as to provide an additionallayer or level of control of chemical reaction related physicochemicalprocesses of mass and heat transfer, mixing, degradation, and catalyticchemical conversion, taking place during operation of the chemicalreactor.
 15. The reactor rotary mixing assembly of claim 14, whereinsaid openings are in a form of holes or slits passing entirely throughthe radially curved thickness of said at least one of said rotor blades.16. The reactor rotary mixing assembly of claim 14, wherein saidprotrusions are in a form of teeth or spikes, or mounds protruding orprojecting out from the radially curved thickness of said at least oneof said rotor blades.
 17. The reactor rotary mixing assembly of claim14, wherein said depressions are in a form of inverse mounds protrudingor projecting partly into, not entirely through, the radially curvedthickness of said at least one of said rotor blades.
 18. The reactorrotary mixing assembly of claim 13, wherein said rotor centralreinforcement disc is configured with at least one rotor-basedperformance and process control structural feature selected from thegroup consisting of: openings, protrusions, and depressions, wherebysaid rotor-based performance and process control structural featuresfacilitate controlling performance of said rotor, so as to provideadditional control of chemical reaction related physicochemicalprocesses of mass and heat transfer, mixing, degradation, and catalyticchemical conversion, taking place during operation of the chemicalreactor.
 19. The reactor rotary mixing assembly of claim 18, whereinsaid openings are in a form of holes or slits passing entirely throughthe thickness of said rotor central reinforcement disc.
 20. The reactorrotary mixing assembly of claim 18, wherein said protrusions are in aform of teeth or spikes, or mounds protruding or projecting out from thethickness of said rotor central reinforcement disc.
 21. The reactorrotary mixing assembly of claim 18, wherein said depressions are in aform of inverse mounds protruding or projecting partly into, notentirely through, the thickness of said rotor central reinforcementdisc.
 22. A reactor rotary mixing assembly, for use in a chemicalreactor with high speed rotary mixing, for catalytic thermal conversionof organic materials into diesel and other liquid fuels, the reactorrotary mixing assembly comprising: a rotor, configured with a rotortubular portion longitudinally extending proximally and distally withproximal and distal open ends, said rotor includes a plurality ofradially curved rotor blades, that extend radially from, andlongitudinally along, the outer circumferential periphery of said rotortubular portion; proximal and distal rotatable dynamic seals, configuredwith respective longitudinally directed rotor shaft passageways, andlocated opposite to each other with said rotor tubular memberlongitudinally positioned therebetween; proximal and distal rotatablelubricated cartridge seals, configured with respective longitudinallydirected rotor shaft passageways, and located opposite to each otherwith said proximal and distal dynamic seals longitudinally positionedtherebetween; and a rotatable rotor shaft, longitudinally passingthrough said rotor proximal and distal open ends, and through said rotorshaft passageways of said proximal and distal dynamic seals, and of saidproximal and distal lubricated cartridge seals, said rotor shaft isfixedly connected to said rotor tubular portion so as to facilitatecontrollable rotation of said rotor during operation of the chemicalreactor; wherein at least one of said rotor blades is configured with atleast one rotor-based performance and process control structural featureselected from the group consisting of: openings, protrusions, anddepressions, whereby said rotor-based performance and process controlstructural features facilitate controlling performance of said rotor, soas to provide an additional layer or level of control of chemicalreaction related physicochemical processes of mass and heat transfer,mixing, degradation, and catalytic chemical conversion, taking placeduring operation of the chemical reactor.
 23. The reactor rotary mixingassembly of claim 22, wherein said openings are in a form of holes orslits passing entirely through the radially curved thickness of said atleast one of said rotor blades.
 24. The reactor rotary mixing assemblyof claim 22, wherein said protrusions are in a form of teeth or spikes,or mounds protruding or projecting out from the radially curvedthickness of said at least one of said rotor blades.
 25. The reactorrotary mixing assembly of claim 22, wherein said depressions are in aform of inverse mounds protruding or projecting partly into, notentirely through, the radially curved thickness of said at least one ofsaid rotor blades.
 26. The reactor rotary mixing assembly of claim 22,wherein said rotor includes a rotor central reinforcement disc, havingproximal and distal circular faces, and a central opening concentricwith the circumferential periphery of said rotor tubular portion,thereby facilitating longitudinal passage therethrough of said rotorshaft.
 27. The reactor rotary mixing assembly of claim 26, wherein saidrotor central reinforcement disc is configured with at least onerotor-based performance and process control structural feature selectedfrom the group consisting of: openings, protrusions, and depressions,whereby said rotor-based performance and process control structuralfeatures facilitate controlling performance of said rotor, so as toprovide additional control of chemical reaction related physicochemicalprocesses of mass and heat transfer, mixing, degradation, and catalyticchemical conversion, taking place during operation of the chemicalreactor.
 28. The reactor rotary mixing assembly of claim 27, whereinsaid openings are in a form of holes or slits passing entirely throughthe thickness of said rotor central reinforcement disc.
 29. The reactorrotary mixing assembly of claim 27, wherein said protrusions are in aform of teeth or spikes, or mounds protruding or projecting out from thethickness of said rotor central reinforcement disc.
 30. The reactorrotary mixing assembly of claim 27, wherein said depressions are in aform of inverse mounds protruding or projecting partly into, notentirely through, the thickness of said rotor central reinforcementdisc.